TK2000 NP205 29 Spline Master Overhaul Kit for 1989-1993

TK2000 Torque King® NP205 Transfer Case Master Overhaul Kit with Small Parts and Shims for 1989-1993 29 Spline Input Dodge W250 and W350 Models with Cummins Diesel and 5 Speed Manual Transmission is the highest quality and most complete NP205 overhaul kit available for your rugged Dodge New Process NP205 transfer case bar none. Your Torque King® NP205 Master Overhaul Kit will be custom assembled here in Montana using the best quality components available for your exact 1980-1993 Dodge Ram 23 spline input NP205 transfer case bolted to either an automatic or 4 speed manual transmission. Your Torque King® Kit will include: USA or Canada Made Ball Bearings, Timken® Tapered Roller Bearings, Torrington® Straight Roller Bearings, Original Equipment Spec Precision Thickness Gaskets (critically important for bearing clearances), 8 Case Access Hole Plugs, 4 Low Gear Thrust Washers, 2 Thrust Washer Anti-Rotation Pins, Selective Fit Lock Rings, 2 Detent Springs, 2 Detent Balls, 2 OE Type Shift Fork Roll Pins, Front Output Shaft Nut for Dodge applications with CV flange, Idler Shaft Shim Selection from 0.004"-0.040", Genuine NPG, National® and-or Chicago Rawhide® Input, Output, and Shift Rail Seals, Genuine NPG Spline Seals for 32 spline Yokes, RTV Sealant, and Threadlocker. Nearly all components Made in U.S.A., but some pieces are imported. Kits are assembled with the correct components for your specific Dodge NP205 Transfer Case.

Also See: TK2054 Gasket and Seal Kit

Need More Info? Use the handy Links below to access over 40 years of Dan's product and vehicle specific Tech Notes to easily get the information you need for your vehicle's repair, maintenance, or upgrade project!

Dan the Gear Man® Tech Notes:
Master Overhaul Kits
Small Parts Kits
NP205 Transfer Cases
Special Rear Output Seal
RTV Sealant
End-Play
Applications

Tech Note 1: Master Overhaul Kits
Our Torque King® Premium quality Master Overhaul Kits are the highest quality and most complete NP205 Rebuild Kits you can buy bar none. Competitive Kits use parts that do not even come close to meeting original equipment specifications to achieve the lower price when compared to original equipment parts such as those found in our Torque King® Master Overhaul Kits. To help you make an informed decision on which Kits best meet your needs, read the Tech Notes for Ball Bearings, Needle and Taper Bearings, Gaskets, and Seals to learn about some of the differences between our Premium Original Equipment quality Torque King® Kits and Custom QUADKIT™ sets that we sell as a lower cost option for our local, over the counter retail customers to compete with the low cost kits sold in Billings, MT. Since our Custom Kits use pretty much the same components as the other guys, you can compare the features of our Torque King® Premium Master Overhaul Kits with competitive NP205 Bearing and Seal Kits. (At this time, we do not offer the Custom Kits online.)

Tech Note 2: Small Parts Kits
Due to the large number of NP205 variants, the actual component parts of our model specific Master Overhaul Kits will vary, however, the Torque King® Kit for your NP205 will include all the bearings, gaskets, oil seals, thrust washers, shaft snap rings, and small wearable parts, plus Kits for 32 spline input/output shafts with fixed yokes include the spline seals. Click Here for a list of of the Small Parts in TK2000 Kits.

Tech Note 3: NP205 Transfer Cases
Dodge used a remote (divorced) mount NP205 from 1969-1974 (a few early 1975 trucks may also have them) when it was replaced by the full-time NP203 which was used through 1979. Dodge reintroduced the NP205 for the 1980 model year in a direct mount (married) version with a 23 spline input shaft for use in heavy-duty W250 and W350 4x4 trucks. The 23 spline configuration was joined by a 29 spline input model in 1989. The 29 spline NP205 was only used in W250 and W350 trucks with Cummins Diesel and 5 speed manual transmissions. Dodge dropped the NP205 at the end of the 1993 model year. International only used remote (divorced) mount NP205s from 1969 until light truck production ended in 1975.

Tech Note 4: Special Rear Output Seal
For maximum sealing of your fixed rear output yoke or remote mount input and front output yokes with 2-1/8" hubs, order a pair of our optional TK50092 Special Rear Output Seal which can be doubled for 2-1/8" input/output yoke applications.

Tech Note 5: RTV Sealant
Except for the PTO cover on later production models, NO RTV sealant was used on the NP205 Transfer Case or adapter. All shaft, coupler, and bearing clearances were designed for specific thickness cut paper gaskets. We include a small tube of RTV Sealant if wish to seal the PTO cover with RTV in lieu of a gasket. RTV sealant SHOULD NOT be used to replace any other NP205 gasket, however, you can use a VERY thin film on one side of a gasket to hold it in place during assembly or to fill in gouges in mating surfaces.

Tech Note 6: End-Play
Input Shaft End-Play on direct mount models and rear output shaft end-play on 1980-1991 GM units with slip yokes is minimized by the use of selective fit snap rings. You want to use the thickest available ring that will fit in the shaft groove with the ball bearing installed. There is no published specification for NP205 input or output shaft end-play. Typically, there will be a fair amount of noticeable end-play due to movement of the ball bearings in the case bores.

Applications
Dodge:
Dodge W250, W350 with Cummins Diesel and 5 Speed Manual Transmissions and 29 Spline Input Shaft New Process NP205 Part Time Transfer Cases: 1989, 1990, 1991, 1992, 1993