Chrysler Full-Size Trucks 1967-1988 Repair Guide

Transfer Case Assembly

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REMOVAL & INSTALLATION



Excluding New Process 203
  1. Remove the skid plate, if any.
  2.  
  3. Drain the transfer case by removing the bottom bolt from the front output rear cover.
  4.  
  5. Disconnect the speedometer cable.
  6.  
  7. Matchmark, then disconnect the front and rear output shafts. Suspend these from a convenient location; do not allow them to hang free.
  8.  
  9. Disconnect the shift rods at the transfer case.
  10.  
  11. Support the transmission with a jack and remove the rear crossmember if necessary.
  12.  
  13. Disconnect the front and rear propeller shafts at the transfer case yokes. Secure the shafts with wire, do not allow them to hang.
  14.  
  15. Disconnect the parking brake cable guide from the pivot if necessary.
  16.  
  17. Remove the bolts attaching the exhaust pipe support bracket to the transfer case, if necessary.
  18.  
  19. Remove the adapter-to-transfer case mounting bolts and move the transfer case rearward to disengage the front input splines.
  20.  
  21. Remove any traces of gasket material from the rear of the transmission adapter housing.
  22.  

To install:
  1. Using a sealer, apply to both sides of the transfer case-to-transmission gasket, then position the gasket on the transmission.
  2.  
  3. Align and install the transfer case assembly to the transmission. Be sure the case input gear splines are aligned with the transmission output shaft.
  4.  

Do not install any of the transfer case attaching bolts until the transfer case is completely seated against the transmission.

  1. Align and install the transfer case attaching bolts.
  2.  
  3. Install the rear crossmember, if removed, then remove the transmission support stand.
  4.  
  5. Install the exhaust pipe support bracket if removed, align and connect the propeller shafts.
  6.  
  7. Connect the parking brake cable guide to pivot bracket if removed.
  8.  
  9. Connect the speedometer cable.
  10.  
  11. Connect the shift rods onto the transfer case.
  12.  
  13. Make sure the drain plug is installed and fill transfer case with fresh fluid.
  14.  
  15. Replace the skid plate, if equipped.
  16.  
  17. Adjust the linkage. Lower the truck, test drive.
  18.  

New Process 203
  1. Raise and support the truck.
  2.  
  3. Drain the transfer case of fluid.
  4.  
  5. There are 4 skid plate attaching bolts, remove them.
  6.  
  7. Remove the 5 bolts attaching the front end of the skid plate to the transmission crossmember. Remove the skid plate.
  8.  

Some vehicles do not have a skid plate. Disregard steps 1 and 2 if your truck is not equipped.

  1. Remove the bottom bolt from the output rear cover and allow the case to drain before proceeding.
  2.  
  3. Disconnect the speedometer cable.
  4.  
  5. Disconnect and secure the front and rear output shafts. Disconnect the shift rods at the transfer case.
  6.  
  7. Remove the adaptor-to-transfer case bolts. Move the case rearwards to disengage the front input spline.
  8.  
  9. With a 1 5 / 16 in. socket loosen and remove the rear output shaft yoke nut.
  10.  
  11. Remove the output shaft bearing retainer bolts. Remove the retainer and discard of the gasket.
  12.  
  13. With a hoist or suitable lifting devise lower the transfer case and remove from the truck.
  14.  
  15. Installation is reverse of removal.
  16.  

ADJUSTMENTS



New Process Model T-200 De-Clutch and Shift Rod

See Figure 1

  1. Locate the shift lever in the HIGH SPEED position and the de-clutch lever in the DISENGAGED position.
  2.  
  3. Adjust the shift rod clevis until there is a clearance of approximately 1 / 2 in. (12mm) between the lever and the end of the floor slot.
  4.  
  5. Adjust the de-clutch rod clevis until there is a minimum clearance of 1 / 2 in. (12mm) between the protrusions on the shift and de-clutch levers.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Control rod adjustment


WARNING
A clearance of less than1/2in. (12mm) between the lever protrusions may cause the de-clutch lever to shift when applying the parking brake.

New Process Model NP-201 De-Clutch and Shift Rod

See Figure 2

All adjustments must be made with the front axle engaged and the transfer case in low range.

  1. Disconnect the de-clutch and shift rods at the shift levers.
  2.  
  3. Adjust the de-clutch rod length until the lever clears the rear end of the slot in the cab underbody by 5 / 8 in. (15mm). Secure the adjusting yoke with a locknut.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Linkage adjustments

  1. Adjust the shift rod length until the distance between the protrusions on the shift and de-clutch levers is 1 / 4 in. (6mm). Secure the adjusting yoke with the locknut.
  2.  
  3. Connect the de-clutch and shift rods at the shift levers and then road test the vehicle.
  4.  

New Process Model NP-205

See Figure 3

Refer to the illustration for number reference.



Click image to see an enlarged view

Fig. Fig. 3: Linkage adjustment on NP205

  1. Install the lower shift lever (3) to bracket (1).
  2.  
  3. Mount the bracket (1) loose to adapter.
  4.  
  5. Install the shift rod (4).
  6.  
  7. Position bracket (1) as far forward as possible and tighten bracket screw (2).
  8.  
  9. Cycle shift lever (3) to check for proper function.
  10.  

NP208 and NP241

See Figures 4 and 5

Please refer to the accompanying illustrations for adjustments on the NP208 and NP241 transfer cases.



Click image to see an enlarged view

Fig. Fig. 4: Linkage adjustment on NP208



Click image to see an enlarged view

Fig. Fig. 5: Linkage adjustment on NP241

OVERHAUL



New Process Model T-200 Disassembly

The New Process Model T-200 transfer case is a 2-speed gearbox located under a frame crossmember near the center of the chassis. A short driveshaft connects power from the main transmission to the transfer case, which in turn transmits power to the front and rear drive axles.

BRAKE OUTPUT SHAFT
  1. Clean the transfer case and drain the lubricant.
  2.  
  3. Remove the cotter pin and nut at the end of the brake output shaft.
  4.  

Apply the parking brake to keep the shaft from turning.

  1. Remove the attaching cap screws, nuts and washers, then remove the bearing retainer and gasket.
  2.  
  3. Remove the brake drum, support and companion yoke.
  4.  
  5. Remove the retaining nut and the speedometer drive pinion.
  6.  
  7. Remove the oil seal from the brake support.
  8.  
  9. Remove the shaft, rear bearing cone, shims, speedometer drive gear and spacer.
  10.  
  11. If the bearing cups need replacement, drive them out with a brass drift.
  12.  
  13. Remove the vent assembly.
  14.  
  15. Using a suitable puller, remove the front bearing cone.
  16.  
  17. Carefully remove the snapring and bearing rollers from the gear bore.
  18.  

The brake output shaft and gear are serviced as a unit. Do not remove the gear from shaft.

REAR OUTPUT SHAFT

See Figure 6

  1. Remove the yoke cotter pin and nut.
  2.  
  3. Remove the companion yoke, then remove the oil seal.
  4.  

When removing the companion yoke oil seal, use care not to damage the bearing retainer.

  1. Remove the shaft, rear bearing cone, spacer and shims.
  2.  



Click image to see an enlarged view

Fig. Fig. 6: Exploded view of the rear output shaft bearing retainer

  1. Remove the front bearing cone, using a suitable puller.
  2.  
  3. Carefully the remove snapring and bearing rollers from the gear bore.
  4.  

Rear the output shaft and gear are integral. Do not remove the gear from the shaft.

2-SPEED CLUTCH GEAR, SHIFTER FORK AND SHAFT
  1. Remove the safety wire and screw from the shifter fork.
  2.  
  3. Remove the screw, gasket, spring and detent ball.
  4.  
  5. Remove the shifter shaft, fork and 2-speed clutch gear.
  6.  

FRONT OUTPUT CLUTCH GEAR, SHIFTER FORK AND SHAFT
  1. Remove the safety wire and shift fork screw.
  2.  
  3. Remove the screw, gasket, spring and detent ball.
  4.  
  5. Remove the shift shaft, fork and front output clutch gear.
  6.  
  7. Remove the shift shaft oil seals.
  8.  

FRONT OUTPUT SHAFT
  1. Remove the cotter pin and yoke nut.
  2.  
  3. Remove the plain washer and companion yoke.
  4.  
  5. Remove the thrust washer and front output shaft.
  6.  

INPUT SHAFT
  1. Remove the cotter pin and yoke nut.
  2.  
  3. Remove the washer and companion yoke.
  4.  
  5. Carefully remove the input shaft and gear. Hold the gear on the shaft to retain the bearing rollers.
  6.  

BEARINGS AND RETAINERS
  1. Remove the attaching nuts and lock washers, then remove the gaskets and bearing retainers.
  2.  
  3. Remove the companion yoke oil seals from the case.
  4.  
  5. Using a brass drift, drive the ball bearing assemblies out of the case.
  6.  

IDLER GEAR AND SHAFT
  1. Remove the cotter pin and slotted nut at the end of the idler shaft.
  2.  
  3. Remove the screw, cover and gasket at the other end of the shaft.
  4.  
  5. Thread the arbor tool on the idler shaft.
  6.  

Make sure the arbor is firmly seated against the shoulder on the shaft.

  1. Using a soft-faced hammer, drive the idler shaft out of the case.
  2.  
  3. Separate the shaft and arbor, leaving the arbor in the idler gear.
  4.  
  5. Remove the idler gear (with arbor) and bearing.
  6.  
  7. Remove the arbor, bearing cones, spacer and shims from the gear.
  8.  
  9. If necessary to replace the bearing cups, drive them out with a brass drift.
  10.  

New Process Model T-200 Assembly

Assembly of the transfer case is essentially a reversal of the disassembly procedure. However, items such as bearing preload, gasket preparation and oil seal installation must be accomplished before and during the assembly. The items listed below are of utmost importance and must be carefully considered in order to assure proper operation of the transfer case.

BRAKE OUTPUT SHAFT
  1. If new bearing cups are to be installed, remove any burrs, then carefully clean the bores in the retainer. Install the bearing cups with an arbor press.
  2.  

Make certain that cups seat firmly against the shoulders in the retainer bores.

  1. Coat the 15 bearing rollers with gear lubricant and position them in the gear bore. Secure them with a snapring.
  2.  
  3. If new shims are needed when assembling the shaft and retainer, begin with a 0.0365 in. (0.92mm) shim set.
  4.  

The 0.0365 in. (0.92mm) shim set consists of four different sized shims: 0.004, 0.005, 0.0125 and 0.15 in. (0.10, 0.12, 0.31, 3.80mm) one of each.

  1. To check the bearing preload (after shaft and retainer assembly), position the bearing retainer vertically in a soft-jawed vise, so that the shaft can rotate freely. Turn the shaft until the bearing rolls smoothly. Using an inch-pound torque wrench, measure the bearing preload.
  2.  

Make the preload measurement with the wrench in motion.

  1. Add or subtract shims as necessary to meet specifications.
  2.  


WARNING
Incorrect preload will cause shortened bearing life, excessive noise and may promote oil leakage.

  1. After setting the correct bearing preload, remove the slotted nut, washer and yoke. Coat the outer surface of the new oil seal with plastic type gasket cement. Install the oil seal in the brake support, then re-assemble the shaft.
  2.  
  3. When installing the brake support on the bearing retainer, make certain that the studs are tight and that the retainer oil drain holes, gasket cutout and support drain holes are all aligned.
  4.  
  5. Position the speedometer drive pinion so that the pilot at the lower end of the pinion engages the hole in the retainer boss.
  6.  
  7. When positioning the retainer in the transfer case, make certain that the pad on the retainer flange covers the shift shaft opening.
  8.  

REAR OUTPUT SHAFT
  1. If new bearing cups are to be installed, remove any burrs, then carefully clean the bores in the retainer. Install the bearing cups with an arbor press.
  2.  

Make certain that cups seat firmly against the shoulders in the retainer bores.

  1. Measure the bearing preload. If new shims are needed when assembling the shaft and retainer, begin with a 0.0365 in. (0.92mm) shim set.
  2.  

The 0.0365 in. (0.92mm) shim set consists of four different sized shims: 0.004, 0.005, 0.0125 and 0.15 in. (0.10, 0.12, 0.31, 3.80mm)-one of each.

  1. To check the bearing preload (after shaft and retainer assembly), position the bearing retainer vertically in a soft-jawed vise, so that the shaft can rotate freely. Turn the shaft until the bearing rolls smoothly. Using an inch-pound torque wrench, measure the bearing preload.
  2.  

Make the preload measurement with the wrench in motion.

  1. Add or subtract shims as necessary to meet specifications.
  2.  
  3. Position the seal in the bearing retainer with the lip toward inside of the case.
  4.  

IDLER GEAR
  1. The correct adjustment of the idler gear bearing is free rolling, but with no end-play. To achieve this, remove one shim at a time until a slight drag is felt when rotating the shaft. Add a shim just thick enough to permit smooth roller operation.
  2.  
  3. Use the arbor tool to install the idler gear and shaft in the case.
  4.  
  5. When installing the slotted nut at the end of the shaft, tighten, then install cotter pin.
  6.  

Do not back off the nut to align the cotter pin hole. Tighten, if necessary.

FRONT OUTPUT SHAFT

Position the bearing retainer firmly against the case, then measure the clearance with a feeler gauge. Install a combination of gaskets approximately 0.006 in. (0.15mm) more than the measured clearance.

Gaskets are available in two thicknesses: 0.009 in. (0.22mm) and 0.013 in. (0.33mm).

INPUT SHAFT
  1. Install 70 bearing rollers with the spacer in the input shaft gear. Use a sleeve to retain the rollers.
  2.  
  3. Select the bearing retainer gaskets as described under front output shaft.
  4.  

ASSEMBLY SPECS

END-PLAY:





Idler Gear Bearing- 0
 
Input Shaft-0.006 in. (0.15mm)
 
Front Output Shaft-0.006 in. (0.15mm)
 

BEARING PRELOAD:





Brake Output Shaft Bearing-15-30 inch lbs. (1.6-3.3 Nm)
 
Rear Output Shaft Bearing-15-30 inch lbs. (1.6-3.3 Nm)
 

TORQUE LIMITS:





Brake Output Shaft Yoke Nut-140-160 ft. lbs. (189-216 Nm)
 
Rear Output Shaft Yoke Nut-140-160 ft. lbs. (189-216 Nm)
 
Idler Shaft Nut-140-160 ft. lbs. (189-216 Nm)
 
Bearing Retainer Cap Screws-30-35 ft. lbs. (40.6-47.4 Nm)
 
Case Mounting Bolts-50-55 ft. lbs. (67-74 Nm)
 

New Process Model NP-201 Disassembly

See Figure 7

The New Process Model NP-201 transfer case is a 2-speed gearbox which provides speed reduction and couples power to the front and rear driving axles.


WARNING
Do not engage the front driving axle when operating the truck on hard surfaced roads at high speeds.



Click image to see an enlarged view

Fig. Fig. 7: Exploded view of NP201

REAR OUTPUT SHAFT
  1. Remove the cotter pin and flange nut at the rear output shaft.
  2.  
  3. Remove the attaching bolts and nuts, then remove the bearing retainer and gasket. Discard the gasket.
  4.  
  5. Remove the output shaft assembly from the case.
  6.  
  7. Remove the nut and washer at the rear of the shaft.
  8.  
  9. Remove the brake drum by tapping on it lightly (if necessary).
  10.  
  11. Remove the shaft and gear from the bearing retainer.
  12.  
  13. Remove the shims, spacer and speedometer drive gear. Tie the shims together for re-assembly.
  14.  
  15. Remove the inner bearing cone, using a suitable puller.
  16.  
  17. Remove the snapring and roller bearings from the shaft gear bore.
  18.  


WARNING
The rear output shaft and gear is serviced as an assembly. Do not remove the gear from the shaft.

  1. Remove the attaching nuts, brake support, bearing and oil seal. Discard of the seal.
  2.  

FRONT OUTPUT SHAFT
  1. Remove attaching bolts and nuts, then the rear bearing retainer and gasket. Discard the gasket.
  2.  
  3. Remove the cotter pin and nut at the front output shaft.
  4.  
  5. Remove the attaching nut, washer and companion flange.
  6.  
  7. Remove the front output shaft assembly through the rear of the case.
  8.  
  9. Remove the sliding clutch gear.
  10.  
  11. Position the shaft assembly in a soft-jawed vise.
  12.  
  13. Remove the lock retainer and bearing nut.
  14.  
  15. Using a suitable puller, remove the bearing.
  16.  
  17. Remove the front output shaft drive gear by lifting upward and holding the thrust washers against the hub to retain the bearing rollers.
  18.  
  19. Carefully set aside the thrust washers, then remove the two rows of bearing rollers and the spacer separating them.
  20.  
  21. Remove the attaching nuts and bearing retainer with the gaskets. Note number of gaskets used.
  22.  

IDLER GEAR, SHIFT BAR AND FORK
  1. Remove the safety wire and setscrews securing the shift forks to the shift bars.
  2.  
  3. Remove the detent ball retaining plugs, gaskets and detent ball springs.
  4.  
  5. Pull the shift bars out of the case, then remove the shift forks and detent balls.
  6.  
  7. Remove the cotter pin, nut and washer from the front end of the shaft.
  8.  
  9. Remove the attaching bolts, gasket and idler gear shaft cover plate.
  10.  
  11. When removing the idler gear assembly, use an arbor, and perform the following. Then, remove the idler gear assembly:
    1. Install the arbor on the threaded end of shaft so that it seats against the shaft shoulder.
    2.  
    3. Drive the arbor until the shaft is free at the rear of the case.
    4.  
    5. Separate the shaft and arbor.
    6.  
    7. Remove the gear with the arbor through the front output shaft opening.
    8.  
    9. Remove the arbor, shims, spacer and bearing cones. Tie the shims together for re-assembly.
    10.  

  12.  

INPUT SHAFT
  1. Remove the cotter pin and input shaft flange nut.
  2.  
  3. Remove the nut, flat washer and companion flange.
  4.  
  5. Remove the input shaft assembly through the rear output shaft opening in the case.
  6.  

Make certain to retain the power take-off and drive gear on the shaft.

  1. Mount the input shaft in a soft-jawed vise.
  2.  
  3. Remove the power take-off gear.
  4.  
  5. Remove the input drive gear while holding the thrust washers tightly against the hub.
  6.  
  7. Carefully remove the two rows of bearing rollers and the separating spacers. Do not drop them its a mess.
  8.  
  9. Remove the attaching nuts, bearing retainer, gaskets and oil seal. Note the number of gaskets used and discard of the oil seal.
  10.  

New Process Model NP-201 Assembly

The transfer case is assembled in the reverse order of disassembly. The following procedures, however, must all be completed before (or in some cases, during) installation of shaft and gear assemblies.

INPUT SHAFT
  1. The input shaft drive gear bearing consists of 70 rollers divided into two rows by a spacer.
  2.  
  3. Coat the gear bore with grease, then position the rollers and spacer. Do not drop any; 70 is a lot to find and count.
  4.  
  5. Hold the thrust washers against the hub to retain the rollers, then install the gear on the shaft.
  6.  
  7. Input shaft end-play is controlled by the gasket thickness between the case and the bearing retainer.
  8.  
  9. Position the retainer on the case, then measure the clearance with a feeler gauge.
  10.  
  11. Select gasket(s) with a thickness 0.005 in. (0.12mm) more than the measured clearance.
  12.  
  13. Remove the retainer and install the selected gasket(s), then reinstall the retainer.
  14.  

REAR OUTPUT SHAFT
  1. Rear output shaft bearing preload is set by the shim set size selection.
  2.  
  3. Using an arbor press and suitable sleeve, install the inner bearing on the shaft. The cone should be firmly seated against the gear.
  4.  
  5. Install the speedometer drive gear, spacer and original bearing shim set.
  6.  
  7. Install the rear output shaft in the bearing retainer, then position the outer bearing cone on the shaft.
  8.  
  9. Install the parking brake drum, flat washer and slotted nut. Torque the nut to 20 ft.lbs. (169 Nm).
  10.  
  11. Mount the shaft and retainer assembly in a vise so that the shaft is free to rotate.
  12.  
  13. Turn the shaft until the bearing rolls smoothly. Then, using an inch-pound torque wrench, measure the bearing preload. Subtract or add shims as necessary.
  14.  

Shims for adjusting bearing preload are available in three thicknesses.

  1. After the final adjustment, remove the slotted nut, washer and brake drum.
  2.  
  3. Install the parking brake support and new support oil seal.
  4.  
  5. Install the brake drum, washer and slotted nut. Tighten the nut.
  6.  

IDLER GEAR
  1. Idler gear bearing end-play is controlled by shim set size selection.
  2.  
  3. Clamp the idler gear shaft (large end) in a soft-jawed vise.
  4.  
  5. Install the bearing cone against the shoulder on shaft.
  6.  
  7. Install the bearing spacer and original shim set.
  8.  
  9. Install the idler gear (small end down) on shaft, then install the other bearing cone.
  10.  
  11. Position the spacer tool, then install the flat washer and nut. Tighten the nut.
  12.  
  13. Rotate the gear until the bearing rolls smoothly. Then, using a dial indicator, measure the idler gear bearing end-play. Add or subtract shims as necessary to meet specifications.
  14.  
  15. Disassemble the idler gear shaft assembly. Tie the newly selected shims together.
  16.  

To install:
  1. Position the bearing cone in the large end of the gear, then place the gear (small end up) on a bench.
  2.  
  3. Install the same arbor used to remove idler gear shaft, a spacer, new shims and the other bearing cone in the idler gear.
  4.  
  5. Hold the idler gear assembly in the case with the small diameter gear facing rearward, then insert the shaft through the case (from rear) and thread it into the previously installed arbor.
  6.  
  7. Tap on the shaft until arbor extends through opposite side of case.
  8.  
  9. Remove the arbor.
  10.  

TWO-SPEED CLUTCH

When installing the two-speed clutch on the input shaft, make certain that the recessed side of the gear is toward the front of the case.

FRONT OUTPUT SHAFT
  1. The front output shaft drive gear bearing consists of 70 bearing rollers divided into two rows by a spacer.
  2.  
  3. Coat the gear bore with grease, then position the rollers and spacers.
  4.  
  5. Hold the thrust washers against each hub to retain the rollers, then install the gear on the shaft.
  6.  
  7. Shaft end-play is controlled by the gasket thickness between the case and bearing retainer.
  8.  
  9. Position the retainer on case, then measure the clearance with a feeler gauge.
  10.  
  11. Select gasket(s) with a thickness 0.005 in. (0.12mm) more than the measured clearance.
  12.  
  13. Remove the retainer and install the selected gasket(s), then reinstall the retainer.
  14.  
  15. When installing the front output shaft assembly in the case, locate the front output shift bar as far toward the rear of the case as possible. This will make it possible to position the shift fork in the clutch gear collar and to align the clutch gear splines on the front output shaft.
  16.  

ASSEMBLY SPECS

END-PLAY:





Input Shaft-0.005 in. (0.12mm)
 
Front Output Shaft-0.005 (0.12mm)
 
Idler Gear-0-0.002 (0-0.05mm)
 

BEARING PRELOAD:





Rear Output Shaft Bearings-15-30 inch lbs. (1.6 Nm)
 

TORQUE LIMITS:





Front Retainer Nut-35-55 ft. lbs. (47-74 Nm)
 
Poppet Screw-15-25 ft. lbs. (20-33 Nm)
 
Idler Cover Screw-15-25 ft. lbs. (20-33 Nm)
 
Drain and Filler Plugs-25-45 ft. lbs. (33-61 Nm)
 
Top Cover-38-42 ft. lbs. (51-57 Nm)
 
All Bearing Caps-38-42 ft. lbs. (51-57 Nm)
 
Flange and Idler Shaft Nut-125 ft. lbs. (169 Nm)
 
Input Shaft-300-400 ft. lbs. (406-542 Nm)
 
Front Output Shaft-300-400 ft. lbs. (406-542 Nm)
 
Rear Output Shaft-300-400 ft. lbs. (406-542 Nm)
 
Idler Shaft Nut-140-160 ft. lbs. (189-216 Nm)
 
Front Output Shaft Flange Nut-140-160 ft. lbs. (189-216 Nm)
 
Input Shaft Flange Nut-140-160 ft. lbs. (189-216 Nm)
 
Driveshaft Mating Flange Nuts-35 ft. lbs. (47 Nm)
 
Breather-8-12 ft. lbs. (11-16 Nm)
 
Brake Support Nut-25-45 ft. lbs. (33-61 Nm)
 
Brake Retaining Screw-20-40 ft. lbs. (27-54 Nm)
 
Brake Retainer Nut-25-45 ft. lbs. (33-61 Nm)
 
Brake Drum-60-66 ft. lbs. (81-89 Nm)
 
Brake Mounting-60-66 ft. lbs. (81-89 Nm)
 
Brake Drum Nut-140-160 ft. lbs. (189-216 Nm)
 
P.T.O. Screw-8-12 ft. lbs. (10-16 Nm)
 
P.T.O. to Case-38-42 ft. lbs. (51-57 Nm)
 
P.T.O. to Bearing Cap-38-42 ft. lbs. (51-57 Nm)
 
P.T.O. to Top Cover-38-42 ft. lbs. (51-57 Nm)
 
P.T.O. Shaft-300-400 ft. lbs. (406-506 Nm)
 

New Process 203 Disassembly

The New Process Model 203 transfer case is a full-time 4WD unit that operates in 4WD at all times. The unit incorporates a differential similar to axle differentials; compensating for different speeds of the front and rear axles which result from varying speeds while turning and operating over different surfaces.

There are five shift positions with this transfer case; Neutral, High, High Lock, Low, and Low Lock. The Lock positions are used under low traction conditions. In the Lock position, the differential action of the transfer case is eliminated, by locking the front and rear output shafts together. In this mode, neither the front or rear axle can rotate independently of the other.

  1. With a hoist or suitable lifting devise lower the transfer case and remove from the truck.
  2.  
  3. Position the transfer case assembly on blocks with the input shaft facing downward.
  4.  
  5. Place a 1 1 / 2 in.-2 in. (38-50mm) band type hose clamp on the input shaft to retain the bearing.
  6.  
  7. Lift the shift rail and drive out the pin retaining the shift fork.
  8.  
  9. Remove the shift rail detent ball plug, gasket and ball from case. Use a magnet to remove the ball.
  10.  
  11. Push the shift rail down, lift up on the lockout clutch and remove the shift fork from the clutch assembly.
  12.  
  13. Remove the front output shaft rear bearing retainer. It may be necessary to gently tap the front of the shaft or cautiously pry the retainer from the case. Make certain that no roller bearings are lost from the rear cover.
  14.  
  15. When necessary, remove the rear bearing by pressing.
  16.  
  17. Pry the front output shaft front bearing from the lower side of the case.
  18.  
  19. Remove the front output shaft assembly from the case.
  20.  
  21. Lift the intermediate housing from the range box, after removing the bolts.
  22.  
  23. Remove the chain from the intermediate housing.
  24.  
  25. Remove the lockout clutch, drive gear and input shaft from the range box.
  26.  
  27. Install a 1 1 / 2 in.-2 in. (38-50mm) band type hose clamp on the end of the input shaft to retain the roller bearing.
  28.  
  29. Pull up on the shift rail and remove the rail from the link.
  30.  
  31. Lift the input shaft assembly from the range box.
  32.  

New Process 203 Assembly

See Figures 8 and 9

  1. Position the range box with the input gear side down, on wood blocks.
  2.  
  3. Place the gasket on the input housing.
  4.  
  5. Install the lockout clutch and drive sprocket on the input shaft assembly. Install a 2 in. (50mm) band type hose clamp on the end of the input shaft to prevent loss of the bearings during installation.
  6.  
  7. Place the input shaft, lockout clutch and drive sprocket in the range box. Align the tab on the bearing retainer with the notch in the gasket.
  8.  
  9. Engage the lockout clutch shift rail to the connector link. Position the rail in the housing bore and turn the shifter shaft lowering the rail into the housing. This will prevent the link and rail from becoming disconnected.
  10.  
  11. Place the drive chain in the housing with the chain around the outer wall.
  12.  
  13. Secure the chain housing to the range box. Be sure that the shift rail engages the channel of the housing. Place the chain on the input drive sprocket.
  14.  
  15. Place the front output sprocket in the transfer case. Turn the clutch drive gear to assist in positioning the chain on the sprocket.
  16.  
  17. Position the shift fork and rail on the clutch assembly. Install the clutch assembly completely into the drive sprocket. Insert the retaining pin in shift fork and rail.
  18.  
  19. Install the front output bearing, gasket, retainer, bolts, flange, gasket, seal, washer and retaining nut.
  20.  
  21. If the rear bearing was removed from the front output shaft, press a new bearing into the outside face of cover until the bearing is flush with the opening.
  22.  
  23. Install the front output shaft, rear bearing, retainer, gasket and bolts.
  24.  
  25. Slip the differential carrier assembly on the input shaft. The bolts on the carrier must face the rear of the shaft.
  26.  
  27. Load the bearings in the pinion shaft, install the rear output housing assembly, gasket and bolts.
  28.  
  29. Install a dial indicator on the rear housing. The indicator must contact the end of the output shaft. While holding the rear flange, rotate the front output shaft and find the highest point of gear hop. Reset the indicator and with the rear output shaft at the high point, pull up on the the end of the shaft to determine end-play. Remove the indicator and install a shim pack to control end-play to between 0-0.005 in. (0-0.12mm). The shim pack is positioned on the shaft in front of the rear bearing. Check for binding of the rear output shaft.
  30.  
  31. Insert the lockout clutch shift rail detent ball, spring and screw plug in the transfer case.
  32.  
  33. Install the detent plate spring, gasket and plug, if they were not previously installed.
  34.  
  35. Install shift levers on the range box, if these were not left on vehicle.
  36.  



Click image to see an enlarged view

Fig. Fig. 8: Exploded view of components-NP-203



Click image to see an enlarged view

Fig. Fig. 9: Numbered list-exploded view of components for NP-203

  1. Torque all bolts, locknuts and plugs to specifications:
  2.  



Adapter-to-transmission-30 ft. lbs. (40 Nm)
 
Adapter-to-transfer case-30 ft. lbs. (40 Nm)
 
Range box-to-chain case-30 ft. lbs. (40 Nm)
 
Differential housing-to-chain case-30 ft. lbs. (40 Nm)
 
Front input bearing retainer-20 ft. lbs. (27 Nm)
 
Front output bearing retainer-30 ft. lbs. (40 Nm)
 
Differential carrier-55 ft. lbs. (74 Nm)
 
Rear output bearing retainer-30 ft. lbs. (40 Nm)
 
Output shaft yoke-120 ft. lbs. (162 Nm)
 
Lockout shift detent plug-20 ft. lbs. (27 Nm)
 
Range shift detent plug-20 ft. lbs. (27 Nm)
 
PTO cover-15 ft. lbs. (20 Nm)
 
Shifter assembly-to-adapter-30 ft. lbs. (40 Nm)
 
Shift lever-30 ft. lbs. (40 Nm)
 
Range and locknut shift lever locknut-240 inch lbs. (325 Nm)
 
Shift rod swivel clamp-125 inch lbs. (169 Nm)
 
Filler plug-30 ft. lbs. (40 Nm)
 
Adapter-to-insulated plate-150 ft. lbs. (203 Nm)
 
Insulated plate-to-crossmember-150 ft. lbs. (203 Nm)
 
Skid plate-50 ft. lbs. (67 Nm)
 

  1. Fill the transfer case with specified lubricant until the proper level is reached. Secure the filler plug.
  2.  

New Process 203 Component Disassembly
LOCKOUT CLUTCH
  1. Remove the front side gear from the input shaft assembly.
  2.  
  3. Remove the thrust washer, 22 roller bearings, yes (one hundred and twenty-three), and spacers from the front side gear bore. The position of the spacers must be noted.
  4.  
  5. Remove the snapring which holds the drive sprocket to clutch assembly. Slip the drive sprocket from the front side gear.
  6.  
  7. Remove the lower snapring.
  8.  
  9. Remove the sliding gear, spring and spring cup washer from the front side gear.
  10.  
  11. Thoroughly clean and inspect all component parts. Replace any component that is worn or defective.
  12.  

To assemble:
  1. Place the spring cup washer, spring and sliding clutch gear on the front side gear.
  2.  
  3. Secure the sliding clutch to the front side gear with a snapring.
  4.  
  5. Spread petroleum jelly on the front side gear and install all (123) roller bearings and spacers.
  6.  
  7. Place the thrust washer in the gear end of the front side gear.
  8.  
  9. Slide the drive sprocket on the clutch splines and secure with the snapring.
  10.  

DIFFERENTIAL CARRIER
  1. Separate the differential carrier sections, then lift out the pinion gear and spider assembly.
  2.  
  3. Note that the undercut side of the pinion gear spider faces toward the front of the side gear.
  4.  
  5. Remove the pinion thrust washers, pinion roller washer gears and roller bearings from the spider unit.
  6.  
  7. Thoroughly clean and inspect all component parts. Replace any component that is worn or damaged.
  8.  

To assemble:
  1. Spread petroleum jelly on the pinion gears and install the roller bearings, (132) 33 for each pinon.
  2.  
  3. Position on the leg of each spider, pinion roller washer, pinion gear and thrust washer.
  4.  
  5. Position the spider assembly in the front half of the carrier. The undercut surface of the spider thrust surface should face downward or toward teeth.
  6.  
  7. Secure carrier halves together. Make certain the marks are aligned. Torque all bolts.
  8.  

INPUT SHAFT
  1. Remove thrust washer and spacer from the shaft.
  2.  
  3. Remove bearing retainer assembly from the input shaft.
  4.  
  5. Hold the low speed gear and lightly tap the shaft from the gear. Note the position of the thrust washer pins in input shaft.
  6.  
  7. Remove the snapring holding input bearing in retainer using a suitable tool. Lightly tap the rear bearing out of the retainer.
  8.  
  9. Remove the 15 roller bearings and O-ring from end of the input shaft.
  10.  
  11. Thoroughly clean and inspect all component parts. Replace any component that is worn or damaged.
  12.  

To assemble:
  1. Tap or press input bearing into retainer. Be sure that ball loading slots are toward concave side of retainer. Install securing snapring. Make certain that selective snapring of proper thickness is used to provide tightest fit.
  2.  
  3. Position low speed gear on shaft, clutch end facing gear end of input shaft.
  4.  
  5. Place the thrust washers on the input shaft, then align the slot in the washer with the pin in the shaft. Slide or tap the washers into position.
  6.  
  7. Place the input bearing retainer on the shaft and secure with snapring. The snaprings are selective; use snapring that provides tightest fit.
  8.  
  9. Slip spacer and thrust washer on shaft and align with locating pin.
  10.  
  11. Spread heavy grease on end of shaft and install the roller bearings.
  12.  
  13. Install rubber O-ring at end of shaft.
  14.  

RANGE BOX
  1. Remove detent plate spring, plug and gasket.
  2.  
  3. Remove clutch fork and sliding gear by disengaging sliding clutch gear from input gear.
  4.  
  5. Remove upper shift lever from shifter shaft.
  6.  
  7. Remove snapring and lower shift lever.
  8.  
  9. Push shifter shaft assembly down and remove lockout clutch connector link. The long end of connector link engages detent plate.
  10.  
  11. Remove shifter shaft assembly and separate shafts. Remove O-rings.
  12.  
  13. When necessary to remove the detent plate, drive the pivot shaft out then remove the plate and spring from bottom of the case.
  14.  
  15. Remove input gear bearing retainer and seal assembly. Release snapring from retainer and tap bearing out of assembly.
  16.  
  17. Release snapring holding input shaft bearing to shaft and remove bearing.
  18.  
  19. Remove countershaft from cluster gear and case assembly from intermediate case side. Remove cluster gear assembly from range box.
  20.  
  21. Remove cluster gear thrust washers from case.
  22.  
  23. Thoroughly clean and inspect all component parts. Replace any component that is worn or damaged.
  24.  

To assemble:
  1. Spread heavy grease in cluster bore and using proper tool install roller bearings and spacers.
  2.  
  3. Spread heavy grease on case and install thrust washers. Engage tab on thrust washers with slot in case.
  4.  
  5. Place cluster gear assembly in case and install countershaft through front of range box and into gear assembly. Flat face of countershaft must be aligned with case gasket.
  6.  
  7. Place bearing on input gear shaft with snapring groove facing out, install a new retaining ring. Insert input gear and bearing in housing. The retaining ring used in this operation is a select fit. Use ring that provides the tightest fit.
  8.  
  9. Secure input gear and bearing with a snapring.
  10.  
  11. Match up oil slot in retainer with drain hole in case and insert input gear bearing retainer and gaskets. Install bolts and tighten.
  12.  
  13. Spread sealant on pin and install detent pin and pivot pin in housing.
  14.  
  15. Lubricate and install new O-rings on inner and outer shifter shafts.
  16.  
  17. Insert shifter shafts in housing and engage long end of lockout clutch connector link with outer shifter shaft. Complete this operation before assembly bottoms out.
  18.  
  19. Install lower shift lever and retaining ring.
  20.  
  21. Install upper shift lever and shaft retaining nut.
  22.  
  23. Install shift fork and sliding clutch gear. Push fork up into shifter shaft and engage detent plate. Move sliding clutch gear onto input shaft gear.
  24.  
  25. Insert detent plate spring, gasket and plug in housing top. Make certain that spring engages detent plate.
  26.  

INPUT GEAR BEARING
  1. Remove bearing retainer, screws and gasket from housing.
  2.  
  3. Remove and discard snapring holding bearing in retainer.
  4.  
  5. Pry bearing from case and remove from shaft.
  6.  
  7. Remove the 6 cap screws from the PTO cover and remove the cover. This will allow you to inspect input and countergear assemblies. Check for burrs, scoring, and heat discoloration.
  8.  

To assemble:
  1. Inspect input gear and bearing retainer for damage or wear. Replace if necessary.
  2.  
  3. Place new bearing and snapring on input gear. Using a soft hammer, tap bearing into position. Secure snapring.
  4.  
  5. Insert bearing retainer into housing along with a new gasket and secure with attaching bolts. Tighten bolts to 20 ft. lbs. (27mm).
  6.  

INPUT GEAR SEAL
  1. Remove bearing retainer, screws and gasket from housing.
  2.  
  3. Tap or pry the yoke off the shaft.
  4.  
  5. Remove seal from retainer bore by prying.
  6.  
  7. Clean and inspect the retainer.
  8.  

To assemble:
  1. Place new seal on retainer and install with proper seal driver.
  2.  
  3. Install bearing retainer in housing and secure with attaching bolts. Tighten bolts to 20 ft. lbs. (27mm).
  4.  

REAR OUTPUT SHAFT HOUSING
  1. Remove speedometer driven gear from housing.
  2.  
  3. Remove rear output flange and washer, if they have not been removed previously.
  4.  
  5. Using a soft hammer tap on flange end of pinion and remove the pinion. If speedometer drive gear does not come off with pinion reach into case and remove.
  6.  
  7. Remove old seal from bore with suitable prying tool.
  8.  
  9. Remove snapring retaining rear output rear bearing.
  10.  
  11. Tap bearing out of housing.
  12.  
  13. Install a long drift into rear opening of housing and drive out front output bearing. Remove seal and discard.
  14.  
  15. Spread grease on front bearing seal and place in bore. Place bearing in bore and press until it bottoms in housing.
  16.  
  17. Using a soft hammer tap rear bearing into place. Secure with proper snapring. snaprings are selective, use the one that provides the tightest fit.
  18.  
  19. Place rear seal in bore and drive into position with suitable tool. When seal is in position it should be approximately 1 / 8 - 3 / 16 in. (3.0-4.7mm) below housing face.
  20.  
  21. Place speedometer drive gear on output shaft with shims of approximately 0.050 in. (1.2mm) thickness. Insert output shaft into carrier through housing front opening.
  22.  
  23. Install flange and washer on output shaft. Leave retaining nut loose 0.060 in. (1.5mm) until shim requirements are known.
  24.  
  25. Install speedometer driven gear.
  26.  

FRONT OUTPUT SHAFT BEARING SEAL
  1. Remove the output shaft yoke locknut, washer and rubber seal. Tap or pry the yoke off shaft.
  2.  
  3. Remove old seal from retainer bore.
  4.  
  5. Inspect and clean retainer.
  6.  

To install:
  1. Spread sealer on outer edge of new seal.
  2.  
  3. Place new seal in retainer bore and drive into position with proper tool.
  4.  

FRONT OUTPUT REAR BEARING
  1. Remove rear cover from case assembly and discard gasket.
  2.  
  3. Press old bearing from cover.
  4.  

To assemble:
  1. Place new bearing on outside face of cover. Cover bearing with a wood block and press into cover until bearing is flush with opening.
  2.  
  3. Place gasket on transfer case and tap cover into position using a soft hammer. Secure cover with attaching bolts and tighten to specifications.
  4.  

New Process Model 205 Disassembly

The New Process Model 205 transfer case is a two-speed gearbox mounted between the main transmission and the rear axle. The gearbox transmits power from the transmission and engine to the front and rear driving axles.

CASE

See Figures 10 and 11

  1. Clean the exterior of the case.
  2.  
  3. Remove the nuts from the universal joint flanges.
  4.  
  5. Remove the front output shaft rear bearing retainer, front bearing retainer and drive flange.
  6.  



Click image to see an enlarged view

Fig. Fig. 10: Exploded view of the transfer case components

  1. Tap the front output shaft assembly from the case with a soft hammer. Remove the sliding clutch, front output high gear, washer and bearing from the case.
  2.  
  3. Remove the rear output shaft housing attaching bolts, then remove the housing, output shaft, bearing retainer and speedometer gear.
  4.  
  5. Slide the rear output shaft from the housing.
  6.  

Be careful not to lose the 15 needle bearings that will be loose when the rear output shaft is removed.

  1. Drive the two 1 / 4 in. (6.3mm) shift rail pin access hole plugs into the transfer case with a punch and hammer.
  2.  
  3. Remove the two shift rail detent nuts and springs from the case. Use a magnet to remove the two detent balls.
  4.  
  5. Position both shift rails in neutral and remove the shift fork retaining roll pins with a long punch.
  6.  
  7. Remove the clevis pin from one shift rail and rail link.
  8.  
  9. Remove the range shift rail first, then the 4WD shift rail.
  10.  
  11. Remove the shift forks and the sliding clutch from the case. Remove the input shaft bearing retainer, bearing and shaft.
  12.  
  13. Remove the cup plugs and rail pins, if they were driven out, from the case.
  14.  
  15. Remove the locknut from the idler gear shaft.
  16.  
  17. Remove the idler gear shaft rear cover.
  18.  
  19. Remove the idler gear shaft, using a soft hammer and a drift.
  20.  



Click image to see an enlarged view

Fig. Fig. 11: Remove the idler gear shaft with a soft faced hammer

  1. Roll the idler gear assembly to the front output shaft hole and remove the assembly from the case.
  2.  

REAR OUTPUT SHAFT AND YOKE
  1. Loosen the rear output shaft yoke nut.
  2.  
  3. Remove the shaft housing bolts, then remove the housing and the retainer assembly.
  4.  
  5. Remove the retaining nut and yoke from the shaft, then remove the shaft assembly.
  6.  
  7. Remove and discard the snapring.
  8.  
  9. Remove the thrust washer and pin.
  10.  
  11. Remove the tanged bronze washer. Remove the gear needle bearings, spacer, and second row of needle bearings.
  12.  
  13. Remove the tanged bronze thrust washer.
  14.  
  15. Remove the pilot rollers, retainer ring and washer.
  16.  
  17. Remove the oil seal retainer, ball bearing, speedometer gear and spacer. Discard gaskets.
  18.  
  19. Press out bearing.
  20.  
  21. Remove oil seal from the retainer.
  22.  

FRONT OUTPUT SHAFT

See Figure 12

  1. Remove locknut, washer and yoke.
  2.  
  3. Remove attaching bolts and front bearing retainer.
  4.  
  5. Remove rear bearing retainer attaching bolts.
  6.  
  7. Tap output shaft with a soft-faced hammer and remove shaft, gear assembly and rear bearing retainer.
  8.  



Click image to see an enlarged view

Fig. Fig. 12: Removal of the front output shaft

  1. Remove sliding clutch, gear, washer and bearing from output high gear.
  2.  
  3. Remove sliding clutch from the high output gear; then remove gear, washer and bearing.
  4.  
  5. Remove gear retaining snapring from the shaft, using large snapring picks. Discard ring.
  6.  
  7. Remove thrust washer and pin.
  8.  
  9. Remove gear, needle bearings and spacer.
  10.  
  11. Replace rear bearing, if necessary.
  12.  


CAUTION
Always replace the bearing and retainer as an assembly. Do not try to press a new bearing into an old retainer.

SHIFT RAILS AND FORKS

See Figure 13

  1. Remove the two detent nuts, springs, and using a magnet, the detent balls.
  2.  
  3. Remove cup plugs on top of case, using a 1 / 4 in. punch.
  4.  
  5. Position both shift rails in neutral, then remove fork pins with a long handled screw extractor.
  6.  
  7. Remove clevis pins and shift rail link.
  8.  



Click image to see an enlarged view

Fig. Fig. 13: Shift fork pins are removed with a long handled easy-out type tool

  1. Push the shift rails down. lift up on the lockout clutch.
  2.  
  3. Remove shift forks and sliding clutch.
  4.  
  5. Remove the front output high gear, washer and bearing. Remove the shift rail cup plugs.
  6.  

INPUT SHAFT
  1. Remove snapring in front of bearing. Tap shaft out rear of case and bearing out front of case, using a soft-faced hammer or mallet.
  2.  
  3. Tilt case up on power take-off and remove the two interlock pins from inside.
  4.  

IDLER GEAR
  1. Remove idler gear shaft nut.
  2.  
  3. Remove rear cover.
  4.  
  5. Tap out idler gear shaft, using a soft-faced hammer and a drift approximately the same diameter as the shaft.
  6.  
  7. Remove idler gear through the front output shaft hole.
  8.  
  9. Remove two bearing cups from the idler gear.
  10.  

New Process Model 205 Assembly
CASE
  1. Assemble the idler shaft gears, bearings, spacer and shims, and bearings on a dummy shaft tool, then install the assembly into the case through the front output shaft bore, (large end first).
  2.  
  3. Install the idler shaft from the large bore side, using a soft hammer to drive it through the bearings, spacer, gears, and shims.
  4.  
  5. Install a washer and new locknut on the end of the idler shaft. Check to make sure the idler gear rotates freely. Tighten the locknut to 138 ft. lbs. (186 Nm).
  6.  
  7. Install the idler shaft cover with a new gasket so the flat side faces the rear bearing retainer of the front output shaft. Install and tighten the two retaining screws to 20 ft. lbs. (27 Nm).
  8.  
  9. Install the interlock pins into the interlock bore through the front of the output shaft opening.
  10.  
  11. Start the 4WD shift rail into the front of the case, solid end of the rail first, with the detent notches facing up.
  12.  
  13. Position the shift fork onto the shift rail with the long end facing inward. Push the rail through the fork and into the Neutral position.
  14.  
  15. Position the input shaft and bearing in the case.
  16.  
  17. Start the range shift rail into the case from the front, with the detent notches facing up.
  18.  
  19. Position the sliding clutch to the shift fork. Place the sliding clutch on the input shaft and align the fork with the shift rail. Push the rail through the fork into the Neutral position.
  20.  
  21. Install the roll pins that lock the shift forks to the shift rails with a long punch.
  22.  
  23. Position the front wheel drive high gear and its thrust washer in the case. Position the sliding clutch in the shift fork. Shift the rail and fork into the four wheel drive (4WD-Hi) position, while at the same time, meshing the clutch with the mating teeth on the four wheel drive high gear.
  24.  
  25. Align the thrust washer, high gear and sliding clutch with the bearing bore in the case, then insert the front output shaft and low gear into the high gear assembly.
  26.  
  27. Install a new seal in the front bearing retainer of the front output shaft, then install the bearing and retainer and new gasket in the case. Tighten the bearing retainer cap screws to 30 ft. lbs. (40 Nm).
  28.  
  29. Lubricate the roller bearing in the front output shaft rear bearing retainer, which is the aluminum cover, and install it over the front output shaft and to the case. Install and tighten the retaining screws to 30 ft. lbs. (40 Nm).
  30.  
  31. Move the range shift rail to the High position and install the rear output shaft and retainer assembly to the housing and input shaft. Use one or two new gaskets, as required, to adjust the clearance on the input shaft pilot. Install the rear output shaft housing retaining bolts and tighten them to 30 ft. lbs. (40 Nm).
  32.  
  33. Using a punch and sealing compound, install the shift rail pin access plugs.
  34.  
  35. Install the fill and drain plugs and the cross-link clevis pin.
  36.  

IDLER GEAR

See Figure 14

  1. Press the two bearing cups in the idler gear.
  2.  
  3. Assemble the two bearing cones, spacer, shims and idler gear on a dummy shaft, with bore facing up. Check end-play.
  4.  
  5. Install idler gear assembly (with dummy shaft) into the case, large end first, through the front output shaft bore.
  6.  



Click image to see an enlarged view

Fig. Fig. 14: Installation of the idler gear assembly

  1. Install idler shaft from large bore side, driving it through with a soft-faced hammer or mallet.
  2.  
  3. Install washer and new locknut. Check for free rotation and measure end-play. Torque locknut to 138 ft. lbs. (186 Nm).
  4.  
  5. Install idler shaft cover and new gasket. Torque cover bolts to 20 ft. lbs. (27 Nm).
  6.  

Flat side of cover must be positioned towards front output shaft rear cover.

SHIFT RAILS AND FORKS

See Figure 15

  1. Press the two rail seals into the case.
  2.  

Install seals with metal lip outward.

  1. Install interlock pins from inside case.
  2.  
  3. Insert slotted end of front output drive shift rail (with detent notches up) into back of case.
  4.  
  5. While pushing rail through to neutral position, install shift fork (long end inward).
  6.  
  7. Install input shaft and bearing into case.
  8.  
  9. Install end of range rail (with detent notches up) into front of case.
  10.  
  11. Install sliding clutch on fork, then place over input shaft in case.
  12.  
  13. Push range rail, while engaging sliding clutch and fork, through to neutral position.
  14.  
  15. Drive new lockpins into forks through holes at top of case.
  16.  

Tilt case on power take-off opening to install range rail lockpin.

FRONT OUTPUT SHAFT and GEAR

See Figure 16

  1. Install two rows of needle bearings in the front low output gear and retain with grease.
  2.  

Each row consists of 32 needle bearings and the two rows are separated by a spacer.

  1. Position front output shaft in a soft-jaw vise, with spline end down. Place front low gear over shaft with clutch gear facing down; then install thrust washer pin, thrust washer and new snapring.
  2.  

Position snapring gap opposite the thrust washer pin.

  1. Place front drive high gear and washer in case. Install sliding clutch in the shift fork, then put fork and rail into 4-High position, meshing front drive high gear and clutch teeth.
  2.  
  3. Align washer, high gear and sliding clutch and bearing bore. Insert front output shaft and low gear assembly through the high gear assembly.
  4.  
  5. Install front output bearing and retainer with a new seal in the case.
  6.  



Click image to see an enlarged view

Fig. Fig. 15: Removal and installation of the shift rails



Click image to see an enlarged view

Fig. Fig. 16: Snapring pliers are a good tool for removal and installation

  1. Clean and grease rollers in front output rear bearing retainer. Install on case with one gasket and bolts coated with sealant. Torque bolts to 30 ft. lbs. (40 Nm).
  2.  
  3. Install front output yoke, washer and locknut. Torque locknut to 1 ft. lbs. (149 Nm).
  4.  

REAR OUTPUT SHAFT
  1. Install two rows of needle bearings into the output low gear, retaining them with grease.
  2.  

Each row consists of 32 needle bearings and the two rows are separated by a spacer.

  1. Install thrust washer (with tang down in clutch gear groove) onto the rear output shaft.
  2.  
  3. Install output low gear onto shaft with clutch teeth facing downward.
  4.  
  5. Install thrust washer over gear with tab pointing up and away. Install washer pin.
  6.  
  7. Install large thrust washer over shaft and pin. Turn washer until tab fits into slot located approximately 90° away from pin.
  8.  
  9. Install snapring and measure shaft end-play.
  10.  
  11. Grease pilot bore and install needle bearings.
  12.  

There are 15 pilot needle bearings.

  1. Install thrust washer and new snapring in pilot bore.
  2.  
  3. Press new bearing into retainer housing.
  4.  
  5. Install housing on output shaft assembly.
  6.  
  7. Install spacer and speedometer gear. Install rear bearing.
  8.  
  9. Install rear bearing retainer seal.
  10.  
  11. Install bearing retainer assembly on housing, using one or two gaskets to achieve specified clearance. Torque attaching bolts to 30 ft. lbs. (40 Nm).
  12.  
  13. Install yoke, washer and locknut on output shaft. Torque the nut to 138 ft. lbs. (187 Nm).
  14.  
  15. Position range rail in high, then install output shaft and retainer assembly on case. Torque housing bolts to 30 ft. lbs. (40 Nm).
  16.  

CASE
  1. Install power take-off cover and gasket. Torque attaching bolts to 35 ft. lbs. (47 Nm).
  2.  
  3. Install cup plugs at rail pin holes.
  4.  

After installing, seal the cup plugs.

  1. Install drain and filler plugs. Torque to 40 ft. lbs. (54 Nm).
  2.  
  3. Install shift rail cross link, clevis pins and lock pins.
  4.  

New Process 208 Disassembly

See Figures 17, 18 and 19

The NP-208 is a part-time unit with a two piece aluminum housing. On the front case half, the front output shaft, front input shaft, four wheel drive indicator switch and shift lever assembly are located. On the rear case half, the rear output shaft, bearing retainer and drain and fill plugs are located.

  1. Drain the fluid from the case.
  2.  
  3. Matchmark the transfer case yoke and drive-shaft for installation.
  4.  
  5. Remove the attaching nuts from the front and rear output yokes. Remove the yokes and sealing washers.
  6.  
  7. Remove the four bolts and separate the rear bearing retainer from the rear case half.
  8.  
  9. Remove the retaining ring, speedometer drive gear nylon oil pump housing, and oil pump gear from the rear output shaft.
  10.  
  11. Mark the rear retainer for assembly alignment.
  12.  
  13. Remove the eleven bolts and separate the case halves by inserting a small prytool in the pry slots on the case.
  14.  
  15. Remove the magnetic chip collector from the bottom of the rear case half.
  16.  
  17. Remove the thick thrust washer, thrust bearing and thin thrust washer from the front output shaft assembly.
  18.  
  19. Remove the drive chain by pushing the front input shaft inward and by angling the gear slightly to obtain adequate clearance to remove the chain.
  20.  
  21. Remove the output shaft from the front case half and slide the thick thrust washer, thrust bearing and thin thrust washer off the output side of the front output shaft.
  22.  
  23. Remove the screw, detent spring and check ball from the front case half.
  24.  
  25. Remove the four wheel drive indicator switch and washer from the front case half.
  26.  
  27. Position the front case half on the face and lift out the rear output shaft, sliding clutch and clutch shift fork and spring.
  28.  
  29. Place a shop towel on the shift rail. Clamp the rail with a vise grip pliers so that they lay between the rail and the case edge. Position a prybar under the pliers and pry out the shift rail.
  30.  
  31. Remove the snapring and thrust washer from the planetary gear set assembly in the front case half.
  32.  



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Fig. Fig. 17: Mainshaft, drive sprocket, and synchronizer assembly



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Fig. Fig. 18: Planetary thrust washer and planetary assembly



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Fig. Fig. 19: Removal of annulus gear and mode fork

  1. Remove the annulus gear assembly and thrust washer from the front case half.
  2.  
  3. Lift the planetary gear assembly from the front case half.
  4.  
  5. Lift out the thrust bearing, sun gear, thrust bearing and thrust washer.
  6.  
  7. Remove the six bolts and lift the gear locking plate from the front case half.
  8.  
  9. Remove the nut retaining the external shift lever and washer. Press the shift control shaft inward, then remove the shift selector plate and washer from the case.
  10.  
  11. From the rear output shaft, remove the snapring and thrust washer retaining the chain drive sprocket, then slide the sprocket from the drive gear.
  12.  
  13. Remove the retaining ring from the sprocket carrier gear.
  14.  
  15. Carefully slide the sprocket carrier gear from the rear output shaft. Remove the two rows of 60 loose needle bearings. Remove the three separator rings from the output shaft.
  16.  

New Process 208 Assembly

See Figures 20 through 24



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Fig. Fig. 20: Cross-sectional view of the transfer case assembly

  1. Slide the thrust washer against the gear on the rear output shaft.
  2.  
  3. Place the three space rings in position on the rear output shaft. Liberally coat the shaft with petroleum jelly and install the two rows (60 each) of needle bearings in position on the rear output shaft.
  4.  



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Fig. Fig. 21: If you were lucky on installing all of these 18 needle bearings, this is what yours should look like

  1. Carefully slide the sprocket gear carrier over the needle bearings. Be careful not to dislodge any of the needles.
  2.  
  3. Install the retaining ring on the sprocket gear.
  4.  
  5. Slide the chain drive sprocket onto the sprocket carrier gear.
  6.  



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Fig. Fig. 22: Install sprockets and drive chain

  1. Install the thrust washer and snapring on the rear output shaft.
  2.  
  3. Install the shift selector plate and washer through the front of the case.
  4.  
  5. Place the shift lever assembly on the shift control shaft and torque the nut to 14-20 ft. lbs. (18-27 Nm).
  6.  
  7. Place the locking plate in the front case half and torque the bolts to 25-35 ft. lbs. (34 Nm).
  8.  
  9. Place the thrust bearing and washer over the input shaft of the sun gear. Insert the input shaft through the front case half from the inside and insert the thrust bearing.
  10.  



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Fig. Fig. 23: Input thrust bearing and race on NP208

  1. Install the planetary gear assembly so the fixed plate and planetary gears engage the sun gear.
  2.  
  3. Slide the annulus gear and clutch assembly with the shift fork assembly engaged, over the hub of the planetary gear assembly. The shift fork pin must engage the slot in the shift selector plate. Install the thrust washer and snapring.
  4.  
  5. Position the shift rail through the shift fork hub in the front case. Tap lightly with a soft hammer to seat the rail in the hole.
  6.  
  7. Position the sliding clutch shift fork on the shift rail and place the sliding clutch and clutch shift spring into the front case half. Slide the rear output shaft into the case.
  8.  
  9. On the output side of the front output shaft, assemble the thin thrust washer, thrust bearing, and thick thrust washer and partially insert the front output shaft into the case.
  10.  



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Fig. Fig. 24: Front output shaft and front thrust bearing

  1. Place the drive chain on the rear output shaft drive gear. Insert the rear output shaft into the front case half and engage the drive chain on the front output shaft drive gear. Push the front output shaft into position in the case.
  2.  
  3. Assemble the thin thrust washer, thrust bearing and thick thrust washer on the inside of the front output shaft drive gear.
  4.  
  5. Position the magnetic chip collector into position in the front case half.
  6.  
  7. Place a bead of RTV sealant completely around the face of the front case half and assemble the case halves being careful that the shift rail and forward output shafts are properly retained.
  8.  
  9. Alternately tighten the bolts to 20-25 ft. lbs. (27-33 Nm).
  10.  
  11. Slide the oil pump gear over the input shaft and slide the spacer collar into position.
  12.  
  13. Engage the speedometer drive gear onto the rear output shaft and slide the retaining ring into position.
  14.  
  15. Use petroleum jelly to hold the nylon oil pump housing in position at the rear bearing retainer. Apply a bead of RTV sealant around the mounting surface of the retainer and carefully position the retainer assembly over the output shaft and onto the rear case half. The retainer must be installed so that the vent hole is vertical when the case is installed.
  16.  
  17. Torque the retainer bolts alternately to 20-25 ft. lbs. (27-33 Nm).
  18.  
  19. Place a new thrust washer under each yoke and install the yokes on their respective shafts. Place the oil slinger under the front yoke. Torque the nuts to 90-130 ft. lbs. (122-176 Nm).
  20.  
  21. Install the detent ball, spring and screw in the front case half. Torque the screw to 20-25 ft. lbs. (27-33 Nm).
  22.  
  23. Install the 4WD indicator switch and washer and tighten to 15-20 ft. lbs. (20-27 Nm).
  24.  
  25. Add approximately 6 pints of fluid or ATF+3 to the case assembly.
  26.  

New Process 241 Disassembly

The NP-241 is a part-time unit with a two piece aluminum housing. On the front case half, the front output shaft, front input shaft, four wheel drive indicator switch and shift lever assembly are located. On the rear case half, the rear output shaft, bearing retainer and drain and fill plugs are located.

  1. Drain the fluid from the case if not already drained.
  2.  
  3. Remove the attaching nuts from the front and rear output yokes. Matchmark the driveshaft and transfer case yoke. Remove the yokes and sealing washers.
  4.  
  5. Remove the indicator switch and seal, then, remove the speedometer switch and seal.
  6.  
  7. Remove the detent screw, spring and the range selection plunger.
  8.  
  9. Remove the bolts and disconnect the mainshaft extension housing from the rear case half.
  10.  
  11. Remove the retaining ring, speedometer drive gear nylon, oil pump housing, and the oil pump gear from the rear output shaft.
  12.  
  13. Unbolt the case bolts and separate the case halves by inserting a small prybar in the pry slots on the case.
  14.  
  15. Remove the fork shift spring.
  16.  
  17. Remove the oil pump pick-up tube and the magnetic chip collector.
  18.  
  19. Separate the retainer from the driven socket.
  20.  
  21. Remove the mainshaft, chain and driven sprocket as a unit from the front case half.
  22.  
  23. Remove the synchronizer assembly retainer, then remove the synchronizer assembly, sleeve, thrust washer, hub and ring.
  24.  
  25. Remove the range fork, range selector, mode fork and range shift hub. Remove the shift lever nut, washer, and shift lever.
  26.  
  27. Remove the input shaft bearing retainer plate and seal.
  28.  
  29. Remove the input shaft bearing retainer, bearing, and the planetary assembly. Remove the bearing from the input gear with special tool J-22912-1.
  30.  
  31. Remove the retainer, lockring and thrust washer from the annulus gear assembly.
  32.  
  33. Remove the needle bearing from the input gear as follows:
    1. Insert needle bearing tool J-29369-1 and adapter with J-2619-5 slide hammer.
    2.  
    3. Using the tools mentioned above, hammer the bearing from the input gear.
    4.  

  34.  
  35. Remove the drive sprocket from the main driveshaft.
  36.  
  37. Remove the needle bearings from the drive sprocket as follows:
    1. Insert needle bearing tool J-29369-2 and adapter with J-2619-5 slide hammer.
    2.  
    3. Using the tools mentioned above, hammer the bearing from the drive sprocket.
    4.  

  38.  
  39. Remove the retainer and bearing from the front output shaft. Use bearing remover tool J-33832 and driver J-8092 to drive the bearing from the case.
  40.  
  41. Remove the seal from the mainshaft extension housing and the seal from the front input bearing retainer.
  42.  

  1. Remove the needle bearing from the rear case half as follows:
    1. Insert needle bearing tool J-29369-2 and adapter with J-2619-5 slide hammer.
    2.  
    3. Using the tools mentioned above, hammer the bearing from the case.
    4.  

  2.  

New Process 241 Assembly

See Figures 25 through 30

  1. Use tools J-36370 and J-8092 to drive the needle bearings onto the mainshaft drive sprocket.
  2.  
  3. With special tools J-36372 and J-8092, drive the needle bearing into the rear case half.
  4.  
  5. With tools J-36373 and J-8092, drive the needle bearing into the input gear.
  6.  
  7. Install the bearing into the front case half, using J-36371 and J-36373 to insert the bearing. Install the bearing.
  8.  
  9. Use J-36371 and install the bearing into the oil pump housing.
  10.  
  11. Install the bearing to the input gear, then, install the thrust washer, carrier lockring and the retainer. Install the bearing to the input gear with tool J-36372.
  12.  
  13. Install the input gear, bearing and planetary assembly into the annulus ring. Use a hammer and a brass drift to seat the bearing.
  14.  
  15. Install the retainer to the input shaft bearing.
  16.  
  17. Install the retainer to the input gear.
  18.  
  19. Install the input shaft bearing retainer, seal and bolts. Tighten the bolts to 14 ft. lbs. (189 Nm).
  20.  
  21. Install the range shift hub, mode fork, range selector and range fork. Install the shift lever, washer and nut and tighten to 20 ft. lbs. (27 Nm).
  22.  



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Fig. Fig. 25: Input gear bearing



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Fig. Fig. 26: Range fork and hub

  1. Install the drive sprocket and needle bearings to the main driveshaft.
  2.  
  3. Assemble the synchronizer assembly; ring, hub, thrust washer and sleeve, then install the retainer.
  4.  
  5. Install the mainshaft, chain and driven sprocket as a unit into the front case half.
  6.  
  7. Install the retainer to the driven sprocket. Install the shift fork spring.
  8.  
  9. Install the oil pump pick-up, filler and magnetic washer to the rear case half.
  10.  
  11. Apply a bead of Loctite® 515 sealer or equivalent to the case mating surfaces, then connect the rear and front case halves. Install the bolts and tighten to 23 ft. lbs. (31 Nm).
  12.  
  13. Install the speedometer gear retainer, speedometer gear, then the 2nd retainer.
  14.  
  15. Apply a bead of Loctite® 515 sealer or equivalent to the mating surfaces of the pump housing, then connect the housing. Install the bolts and tighten to 30 ft. lbs. (40 Nm).
  16.  
  17. Install the bearing retainer to the mainshaft.
  18.  
  19. Apply a bead of Loctite® 515 sealer or equivalent to the mating surfaces of the extension housing, then connect the housing. Install the bolts and tighten to 23 ft. lbs. (31 Nm).
  20.  
  21. Install the range selector plunger, spring and detent screw.
  22.  
  23. Install the speedometer pick-up switch and seal. Tighten the switch to 23 ft. lbs. (31 Nm).
  24.  
  25. Install the indicator lamp switch and seal. Tighten the switch to 17 ft. lbs. (23 Nm).
  26.  
  27. Install the front output flange, washer and nut. Tighten the nut to 1 ft. lbs. (149 Nm).
  28.  
  29. Install the transaxle into the vehicle.
  30.  
  31. Fill the unit with approximately 4.6 pints of ATF+3 transmission fluid.
  32.  



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Fig. Fig. 27: Front and rear bearings along with drive sprocket



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Fig. Fig. 28: Low range gear



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Fig. Fig. 29: Mainshaft pilot bearing



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Fig. Fig. 30: Synchronizer setup

 
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