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Shop Now for Gears, Shafts, and Coupler Sleeves to fit 1972-1993 Dodge New Process NP205 Transfer Cases in W100, W200, W250, W300, & W350 4x4 trucks. In stock, quick shipping.
Gears: NP205 Transfer Case Low and High Gears sometimes need to be replaced due major wear on the clutch teeth. Wear on the low gear inside bearing bore is even more common. Worn clutch teeth can cause the transfer case to jump out of gear. Worn Low Gear bearing bores can cause shift issues and clunking noises. Idler Gears rarely need replacement unless the transfer case is run short of oil.
Input Shafts: Dodge New Process NP205 Transfer Cases were built in three different input configurations. 1969-1974 Remote Mount cases all use a 32 spline input shaft. For the 1980-1988 model years all Dodge NP205 models have a 23 spline male input shaft. 1989-1993 trucks with the Cummins Diesel and 5 speed manual transmission have a beefy, 29 spline input shaft, all others use the same 23 spline shaft as 1980-1988.
Output Shafts: Dodge New Process NP205 Transfer Cases were all have the same front output shafts.
Three different rear output shafts were used. 1969-1973 transfer cases with straight shift links have a rear output shaft that takes an unsplined steel speedometer gear. For 1972-73 transfer cases with Y-shaped shift links and all 1974 plus 1980-1988 Dodge NP205D transfer cases, a rear output shaft with a splined speedometer mount is used. For the 1989-1993 model years, two different, but dimensionally interchangeable rear output shafts were produced. Gas engine and Diesel/auto trucks still used the older, weaker shaft with long oil slots. The Diesel-5 speed trucks have rear output shaft with oil feed holes instead of slots to handle the torque and shock loads of Cummins engine trucks with manual transmissions.
Splined Couplers: Dodge used male spline NP205 input shafts that utilize a coupler with female splines to connect to the transmission output shaft. These couplers often need replacement due to spline wear, especially with couplers that are not bathed in oil. All our couplers have the locating snap ring(s) installed which insures full spline contact with both the transmission output shaft and transfer case input shaft.
