Disassembly

Fig. 1 Rear view of transfer case. New Process model 205:

1. Loosen rear output shaft yoke nut, then remove rear output shaft housing bolts, housing and retainer assembly from case.

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

2. Remove rear output shaft retaining yoke and nut, then remove shaft assembly from housing.
3. Remove and discard snap ring using tool No. J-23432 or equivalent, then remove thrust washer and washer pin.
4. Remove bronze washer with tang, gear needle bearings (32 per row), spacer and second row of needle bearings from rear output shaft.
5. Remove tanged bronze thrust washer, pilot rollers (15), retainer ring, washer, oil seal retainer, ball bearing, speedometer gear and spacer from rear shaft.
6. Discard all gaskets and press out bearing from rear output shaft.
7. Remove locknut, washer and yoke from front output shaft.
8. Remove front bearing retainer attaching bolts and retainer, then rear bearing retainer attaching bolts from front output shaft.

Fig. 3 Removing front output shaft rear bearing retainer. New Process model 205:

9. Tap output shaft, gear assembly and rear bearing retainer from case with a rubber mallet.

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

10. Remove synchronizer from output high gear, then washer and bearing from case.
11. Remove and discard gear retaining ring from shaft.
12. Remove thrust washer, pin, gear, needle bearings (32 per row) and spacer from shaft. If front output shaft rear bearing must be replaced, remove bearing by supporting cover and pressing out bearing. Press new bearing into position using a block of wood until bearing is flush with opening.
13. Remove two poppet nuts and springs, using a magnet remove poppet balls from top of transfer case.
14. Using a 1/4 inch punch, drive cup plugs into case.

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

15. Place both shift rails in neutral position and drive shift fork pins into case.

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

16. Remove clevis pins, shift rail link and shift rails. Remove upper (range) rail first, then lower (4 wheel) rail.
17. Remove shift forks, sliding clutch, front output high gear, washer, bearing, shift rail cup plugs and pins from case.
18. Remove snap ring in front of bearing, then using a rubber mallet, tap shaft and bearing out of case.
19. Tip case on power takeoff opening and remove two interlock pins from inside of case.
20. Remove idler gear shaft nut and rear cover.

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

21. Remove idler gear shaft using a rubber mallet and tool No. J-23429 or equivalent.
22. Roll idler gear to front output shaft opening and remove gear from case, then remove bearing cups from gear.