TK2026 Master Overhaul Kit for 1973-1979 Ford Direct Mount NP205

TK2026 Torque King® Master Overhaul Kit with Small Parts and Shims for 31 Spline Female Input for 1973-1979 Ford Direct Mount New Process NP205 Transfer Cases is the highest quality and most complete NP205 overhaul kit available for your rugged 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 NP205 application. Your Torque King® Kit will include: American 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, 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 Ford NP205 Transfer Case.

Also see our TK2058 Gasket and Seal Kit
Also See TK2025 Kit to fit 1973-1977.5 Ford Remote Mount, 32 Spline Male Input

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:
Kit Components
Torque King Kits
Small Parts Kits
Output Seals
Ford Transfer Cases
RTV Sealant
Applications

Tech Note 1: Kit Components
TK10503 5 Bolt Gasket
TK10514 4 Bolt Gasket
2 TK10604 8 Bolt Housing Gasket
2 TK10680 Poppet Gasket
TK10687 Idler Gasket
TK20031 6 Bolt Gasket
TK50175 Retainer Gasket
QU50178 PTO Gasket
2 TK10513 32 Spline Seal
TK10517 Input Seal
2 TK50123 Output/Input Seal
QU50543 Output Seal
2 TK50098 Shift Rail Seal
TK50106 Ball Bearing
2 TK50105 Ball Bearing
TK50356 Needle Bearing
TK50357 Needle Bearing
2 TK50346 Idler Gear Bearing Cup
2 TK50347 Idler Gear Bearing
4 QU50224 Large Case Plug
4 QU50162 Access Plug
2 QU50143 Shift Fork Roll Pin
2 QU10316 Anti-Rotation Pin
QU10816 0.090" Shaft Snap Ring
QA2060 Small Parts Kit
QU10891 0.091" Input Snap Ring
QU10892 0.097" Input Snap Ring
QU10893 0.094" Snap Ring
TKA2053 9 Piece Shim Set
QU90005 0.5oz. Black RTV Sealant
S24200 6ml Blue Threadlocker

Tech Note 2: Torque King 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 3: 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 seal(s). Click Here For a list of of the Small Parts in TK2000 Kits.

Tech Note 4: Output Seals
Our 1973-1979 Ford Parts Books list two output seal configurations for direct mount NP205 Transfer Cases depending upon the output yokes used. Most units will use 2-1/8" Seals on both output yokes, however, starting with assembly number D7TA7A195AA, one of the output yokes can take an 1-7/8" Seal (can be front or rear). TK2026 Kit includes two 2-1/8" ID Seals and one 1-7/8" ID Seal. If your transfer case has been modified with 2 CV flanges/yokes so both use 1-7/8" seals you can order one of these extra 1-7/8" individual seals in addition to your Master Kit:
QU20143 1-7/8" ID Wide Shell Ford OEM Output Seal
QU50543 1-7/8" ID Narrow Shell Output Seal (Two can be used for each yoke for maximum oil retention)
TK10510 1-7/8" ID Double Lip, Double Spring Seal (Seals both directions, best for extreme off-roading
TK50092 2-1/8" ID Narrow Shell Output Seal (Two can be used for each yoke for maximum oil retention)
TK50123 2-1/8" Wide, Double Wall Shell OEM Type Output Seal

Tech Note 5: Ford Transfer Cases
Ford used a remote (divorced) mount NP205 in the F250 from 1973-1977.5. Direct mount (married) NP205 models were used in 1973-1979 F100/F150, 1977.5-1979 F-250, 1979 F-350, and 1978-1979 Bronco. During the same years, Ford also used the NP203 full time case (1974-1979), Dana 20 (1973-1978 Bronco), and Dana 21 (early 4 speed F100).

Tech Note 6: 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.

Applications
Ford:
F100, F150: 1973, 1974, 1975, 1976, 1977, 1978, 1979
F250: 1977.5, 1978, 1979
Bronco: 1978, 1979
F350: 1979