Assembly

During assembly, lubricate components with Dexron II automatic transmission fluid.

1. Press bearing cups in idler gear using a shop press.
2. Install two bearing cones, spacer, shims and idler gear on Shaft Tool DD1272 with bore up. Ensure gear endplay is 0.000-0.002 inch.

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

3. Install idler gear assembly, large end first, with dummy shaft into case through front output bore.
4. Install idler shaft from large bore side and tap shaft into gear using a dead-blow hammer. Remove shaft alignment tool as idler pushes it out of gear and case.
5. Install washer and new locknut. Torque locknut to 150 ft. lbs. Check for endplay and free rotation.
6. Install front bearing and snap ring on input gear.
7. Assemble front output shaft. Install gears, sliding clutch, bearings, thrust washer pin, thrust washer, snap ring and retainer on front output shaft.
8. Install interlockpins through large case bore or PTO opening.
9. Install input gear in case, then install sliding clutch on input gear and position shift fork on clutch.
10. Install rear wheel shift rail into case with slotted end first and detent notches facing up, then push rail through shift fork and into opposite end of case.
11. Install front output shaft into case.
12. Install front wheel shift fork in sliding clutch on front shaft, then install front wheel shift rail into case and through shift fork.
13. Secure shift forks to shift rails with new lockpins. Install pins through small bores at top of case.
14. Install front output shaft bearing retainers. Ensure oil drain slot in bearing retainer is aligned with drain hole in case before tightening bolts.
15. Install flange on front shaft. Install seal washer on shaft and install flange locknut finger tight.
16. Install washer, seals gasket and adapter on input shaft.
17. Install shift link and link retaining pins and clips.
18. Assemble rear output shaft and install gears, bearings and spacers.
19. Install new snap ring. Tap ring into seat and check endplay. Endplay should be 0.002-0.027 inch.
20. Install pilot bearing rollers in rear output shaft. Install pilot bearing thrust washer and new snap ring.
21. Install retainer on rear output shaft, speedometer gear and spacer. Install bearing.
22. Install retainer and shaft assembly. Ensure oil drain slot in retainer is aligned with oil drain hole in case. Torque retainer bolts to 40 ft. lbs.
23. Install seals in front and rear seal retainers over shafts and against case. Torque bolts to 40 ft. lbs.
24. Install yoke and flange. Torque yoke and flange nuts to 130 ft. lbs.
25. Install detent balls, springs, plugs, cup plugs and 4WD indicator light switch.
26. Install drain plug and fill transfer case to bottom edge of fill plug hole with suitable lubricant.