Assembly

Fig. 2 Exploded view of New Process model 205 transfer case:

1. Press bearing cups in idler gear using tools No. J-9276-2 and J-8092 or equivalents.
2. Install two bearing cones, spacer, shims and idler gear on dummy shaft J-23429 with bore up. Ensure gear endplay is 0.001-0.002 inch.
3. Install idler gear assembly, large end first, with dummy shaft into case through front output bore.
4. Install idler shaft from large bore side and drive through using a rubber mallet.
5. Install washer and new locknut. Torque locknut to 150 ft. lbs. Check for endplay and free rotation.
6. Install idler shaft cover and gasket. Torque bolts to 20 ft. lbs. Flat on cover must be adjacent to front output shaft rear cover.
7. Press two rail seals, with metal lip outward, into case, then install interlock pins through large bore or power takeoff opening.
8. Install front output drive shift rail into case from back, slotted end first, with poppet notches up.
9. Install shift fork, with long end inward, into rail, then push rail through to neutral position.
10. Install input shaft bearing and shaft into case, then install range rail into case from front with poppet notches up.
11. Install sliding clutch onto fork and place over input shaft in case, then push range rail through to neutral position.
12. Install new lockpins through holes at top of case and drive them into forks. When installing range rail lockpin, tip case on power takeoff opening.
13. Install two rows of needle bearings (32 each), separated by a spacer, in front low output gear. Apply an adequate amount of grease to hold them in place.
14. Secure front output shaft in a soft jawed vise, spline end down.
15. Install front low gear over shaft with clutch gear facing down, then install thrust washer pin, thrust washer and new snap ring using tool No. J-23432 or equivalent. Snap ring opening should be opposite pin.
16. Install front wheel high gear and washer in case.
17. Install synchronizer in shift fork, then place fork and rail in front wheel drive (4-Hi) position with clutch teeth meshed with teeth of front wheel high gear.
18. Line up washer, high gear and synchronizer with bearing bore, then install front output shaft and low gear assembly through high gear assembly.
19. Install new seal in bearing retainer using tool No. J-22836 or equivalent, then install front output bearing and retainer in case.
20. Thoroughly clean and grease rollers in front output rear bearing retainer and install onto case with one gasket. Apply suitable sealant to bolts, then install bolts and torque to 30 ft. lbs.
21. Install front output yoke, washer and locknut. Torque locknut to 150 ft. lbs.
22. Install two rows of needle bearings (32 each), separated by a spacer, into low output gear and apply an adequate amount of grease to hold them in place.
23. Install thrust washer, with tang down, onto rear output shaft in clutch gear groove.
24. Install output low gear onto shaft with clutch teeth facing down, then install thrust washer over gear with tab pointing up and away from gear.
25. Install washer pin and large thrust washer over shaft and pin. Rotate washer until tab fits into slot approximately 90° away from pin, then install snap ring using tools Nos. J-23423 and J-32423-1 or equivalents. Ensure endplay is 0.002-0.027 inch.
26. Grease pilot bore or rear output shaft and install 15 needle bearings, then thrust washer and new snap ring in bore.
27. Clean, grease and install new bearing in retainer housing using tool No. J-23431 or equivalent.
28. Install housing onto output shaft assembly, then install spacer, speedometer gear and bearing.
29. Install rear bearing retainer seal using tools No. J-21359 or J-22834-2 or equivalents.
30. Install bearing retainer assembly with one or two gaskets. Torque bolts to 30 ft. lbs.
31. Install yoke, washer and locknut on output shaft, then place range rail in high and install output shaft and retainer assembly on case. Torque bolts to 30 ft. lbs.
32. Install power takeoff cover and gasket. Torque bolts to 15 ft. lbs.
33. Install and seal, cup plugs at rail pin holes.
34. Install drain and filler plugs and torque to 30 ft. lbs.
35. Install shift rail cross link, clevis pins and lockpins.