TK2074 NP205 Master Overhaul Kit 1986-1991 GM with 32 Spline Input

TK2074 Torque King® Master Overhaul Kit with Small Parts and Shims for 1985-1991 Chevy and GMC New Process NP205 Transfer Cases with 32 Spline Female Input Shafts is the highest quality and most complete NP205 overhaul kit available for your rugged New Process NP205 transfer case bar none. Matching transmission is Turbo 400, 4L8OE Automatic and SM465 4 speed manual transmissions. 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: 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), 4 or 8 Case Access Hole Plugs (depending upon year), 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 Seal for 32 spline fixed rear output Yoke, 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 Chevy or GMC NP205 Transfer Case.

Please Note: The Spline Seals for the early 10 spline and later 30 spline front output yokes are NOT included as these Seals are no longer available.

Also see our TK2052 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:
Highest Quality
Complete Kit
1969-1991 GM Kit Options
GMs and NP205
Synchronized or Non-Synchronized
1982-1987 Synchronized Front Output Only
Reuse Some Existing Parts
For Maximum Sealing
RTV Sealant
Snap Rings
Safety
Applications

Tech Note 1: Highest Quality
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: Complete Kit
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 non-synchronized NP205 will include all the bearings, gaskets, oil seals, thrust washers, shaft snap rings, and small wearable parts, plus Kits for 32 spline rear output shafts with fixed yokes include the spline seal. See Tech Note 5 below for Synchronized Model Exceptions.

Tech Note 3: 1969-1991 GM Kit Options

1. QU30034 Hourglass Gasket with Oil Channel Cutout for Muncie SM465 4 Speed Manual Transmission Main Transmission Case to the FRONT side of the Transmission to Transfer Case Adapter (also known as the Transmission Rear Extension Housing).
2. TK30046 Square cross-section O-Ring for 27 Spline Turbo 350 and 700R4 (4L60) Automatic Transmission Main Transmission Case to the FRONT side of the Transmission to Transfer Case Adapter (also known as Transmission Rear Extension or Bearing Housing).
3. TK30047 6 Bolt Gasket for Turbo 400 Transmission Main Case to the FRONT side of the Transmission to Transfer Case Adapter (also known as Transmission Rear Extension or Bearing Housing) to 1984. Can be used instead of TK30061 O-Ring in 1985-1990 vehicles with Turbo 400 Transmissions.
4. TK30061 square cross-section O-Ring for 1985-1990 Turbo 400 and 1991 4L80E Transmission Main Case to to the FRONT side of the Transmission to Transfer Case Adapter (also known as Transmission Rear Extension or Bearing Housing.
5. QU50435 Ball Bearing for the Turbo 350 Transmission Extension Housing in 1970-1972 GM 4x4s.

Tech Note 4: GMs and NP205
General Motors first used synchronized NP205 in 1982 model year 1 tons. equipped with automatic locking hubs. The synchronized version was intended to provide shift-on-the-fly 4x4 capability with the auto hubs. Unfortunately, it didn't really work out as intended. Most synchronized 205's are in the 1982 and 1983 model year GM 1 tons, however, GM still had enough transfer cases on hand to apparently offer it as an option on 1 ton trucks with auto hubs at least to 1985 and perhaps as late as 1986

Tech Note 5: Synchronized or Non-Synchronized
The easiest way to tell if you have a synchronized or non-synchronized NP205 is to look at the large, 8 bolt round front output, rear cover on the backside of the main case. With non-synchro cases, there is a through hole in the middle of the aluminum cover in which is pressed the front output, rear support bearing. The steel, 2-1/8" diameter, closed end bearing is easy to see in the center of the cover. Synchronized covers are solid and the 1-7/8" OD open end bearing is not visible to the outside, but you will be able to see the raised, solid area of the casting were the bearing is installed

Tech Note 6: 1982-1987 Synchronized Front Output Only
Order the Correct Master Kit for your Year and Input PLUS:
(3) QU10894 Shift Fork Pads
(1) QU50360 Front Output, Rear Support Bearing
(1) QU30081 Front Output, Low Gear Snap Ring

Tech Note 7: Reuse Some Existing Parts
You will have to reuse these parts which are no longer available:
QU30080 Front Output Low Gear Bushing
QU30076 Front Output Low Gear Thrust Washer

Tech Note 8: For Maximum Sealing
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 9: 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 10: Snap Rings
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:
Chevy/GMC:
1985-1991 32 Spline Female Input mates to SM465 4 Speed, Turbo 400, 700R4
(Non-Synchronized 1985-1991, 1985-1987 Synchronized, See Tech Note 5 & 6)
6 Bolt, Round with Shift Rail Notch Adapter to Transfer Case Bolt Pattern
1985-1991 SM465, CH465 4 Speed Manual: See Tech Note 3.1
1985-1990 Turbo 400 Automatic: See Tech Note 3.4
1991 4L-80E Automatic: See Tech Note 3.4