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 rear bearing retainer.
4. Remove rear bearing, speedometer gear, shaft support bearings, thrust washer pin, and low gear from rear output shaft.
5. Remove lock ring thrust washer and pilot bearing rollers from rear output shaft.
6. Remove front yoke nut, washer and flange.
7. Remove front seal retainer and gasket.
8. Remove PTO cover and gasket.
9. Remove detent plug and 4WD indicator light from case.
10. Remove shift rail detent springs and balls. Use a pencil magnet to remove these components.
11. Remove front bearing retainer-to-case attaching bolts.
12. Tap front output shaft with a plastic mallet to loosen it, then remove shaft, retainer and gears.
13. Remove shaft snap ring.
14. Remove adapter and gasket.
15. Remove idler shaft nut and washer, then shaft cover plate and gasket.
16. Using a small punch, remove cup plugs at top of case for access to shift fork lockpins. Remove lockpins from shift forks with a long handled easy-out tool.
17. Remove pins attaching shift rail link, then remove link. Remove shift forks, sliding clutch, front output high gear, washer and bearing.
18. Remove input gear, bearing, seals and washer.
19. Tilt case and roll idler gear toward front shaft opening in case and remove gear through this opening.
20. Remove and retain idler shaft shims. Tie shims together to avoid losing them.
21. Remove interlockpins from inside case. Remove pins through PTO cover opening.
22. If front output shaft rear bearing must be replaced, the bearing and retainer must be replaced as an assembly.