Assembly

Coat gaskets and bolt threads with suitable sealer. Apply transmission oil to all sliding and rotating parts before assembly. Do not reuse spring pins.
1. Press fit control shaft, input gear, and front output shaft oil seals in transfer case, pushing down uniformly on outer circumference, then pack grease between lips.
2. Assemble adapter and transfer case with new gasket, install change shifter over control shaft and torque nuts and bolts to 22-30 ft. lbs. When inserting transmission control shaft through oil seal, be careful not to damage oil seal lip. If change shifter lockpin hole in shaft is burred, remove burrs before inserting shaft through oil seal.
3. Press fit bearing into input gear by pushing down on inner race, then ensure bearing turns freely.
4. Using thickest snap ring that will fit in groove, fit ring over front end of input gear. Snap rings are available in thicknesses of 0.091, 0.093, 0.094, 0.096 and 0.098 inch.
5. Press fit two ball bearings over front output shaft, pushing down inner race, then ensure they turn freely.

Fig. 4 Removing gear retaining ring. New Process model 205:

6. Install ball bearing over rear output shaft from rear end by pushing down inner race, then ensure it turns freely.
7. Mount stop plate and install 2WD-4WD clutch hub and sleeve, noting direction of installation.
8. Mount steel ball for sprocket sleeve positioning on rear output shaft, and install sprocket sleeve.
9. Install two needle bearings on outer circumference of sprocket sleeve, then the drive sprocket.
10. Install steel balls and sprocket spacer, then press fit ball bearing by pushing down inner race and ensure bearing turns freely.
11. Torque mainshaft locknut to 181-195 ft. lbs., drive in detent section, then ensure sprocket turns freely.
12. Install needle bearing, thrust washer and low speed gear on rear output shaft from front.

Fig. 5 Removing shift fork pins. New Process model 205:

13. Install Hi-Lo clutch hub, noting direction of installation.
14. Using thickest snap ring that will fit in groove, install Hi-Lo clutch hub snap ring on front end of rear output shaft. Snap rings are available in thicknesses of 0.084, 0.087, 0.090, 0.093 and 0.095 inch.
15. Install input gear assembly in transfer case, then install thickest snap ring that will fit in groove. Snap rings are available in thicknesses of 0.106, 0.108, 0.110, 0.112 and 0.114 inch.
16. Install needle bearing in input gear.

Fig. 6 Shift rail removed. New Process model 205:

17. Install Hi-Lo clutch sleeve and shift fork noting direction of installation.
18. Install 2WD-4WD shift rail.
19. Securely engage chain with front and rear output shaft sprockets, then assemble 2WD-4WD clutch sleeve with 2WD-4WD shift fork.

Fig. 7 Removing idler gear shaft. New Process model 205:

20. Install clutch sleeve and shift fork assembly over 2WD-4WD shift rail while installing front and rear output shafts with chain.
21. Install two spring retainers and spring on 2WD-4WD shift rail and secure with snap ring.
22. Install two needle bearings and spacer in counter gear, then the assembly in transfer case, installing one thrust washer at front of countergear and other thrust washer at rear.
23. Install countershaft and locking plate.
24. Install side cover and gasket.
25. Install oil guide.
26. Install chain cover and gasket, ensuring oil guide end fits in chain cover opening.
27. Install snap ring in groove of rear output shaft rear bearing.
28. Install interlock plunger.
29. Shift 2WD-4WD shift fork to 4WD side, then install Hi-Lo shift rail through Hi-Lo shift fork.
30. Install two poppet balls with two springs with smaller ends facing balls, then seal plug.
31. Align pin holes of Hi-Lo shift fork and shift rail, then install spring pin so slit is placed on center line of shift rail.
32. Install spacer on rear of rear output shaft bearing, selecting spacer with thickness to set endplay of rear bearing outer race to 0.0-0.04 inch, then install rear cover and gasket. Spacers are available in thicknesses of 0.033, 0.037, 0.040, 0.044, 0.047, 0.051 and 0.054 inch.

Fig. 2 Exploded view of New Process model 205 transfer case:

33. Install pulse generator rotor, if equipped.

Fig. 8 Exploded view of New Process model 208 transfer case:

34. Install wave spring on rear of front output shaft rear bearing, then the cover and gasket. If bearing rear end to cover clearance "C," exceeds 0.079 inch, use appropriate spacer to reduce clearance to 0.079 inch or less.
35. Install speedometer sleeve assembly in rear cover, aligning mating mark on sleeve with mark on case noted during disassembly. The mark on the sleeve coincides with number of teeth of speedometer driven gear.
36. Install sleeve clamp and torque bolt to 7.5-9.0 ft. lbs.
37. Install two 4-wheel drive lamp switches with steel balls, then pulse generator.