I just Started into a transmission rebuild. I got the NP205 off tonight.

Once I got it out I noticed the splines on the NP205 input is toast, worn down and sharp. Transmission out put looks ok.

Both the input and coupler will need to be replaced. The truck has 112,000 miles on it.

Is this a common problem? Any way to keep tis from happening in the future?

One more question. what did the factory do to retain the shifter rod to the transfer case? There was a generic cotter key in there. I am wondering what the factory clip looked like.

Thanks

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That looks like a 29 spline unit form a manual transmission. Your lucky if it is because you can buy new input shaft, and coupler. The 23 spline couplers are no longer available new, at least that I have been able to find.

Was the coupler dry? The lack of lubrication might cause the wear? As for the clip...not sure?

 

TC: The coupler IS dry on the Getrag/205 combination.

I have seen a few worn like this. But I have seen others with many more miles that were un-worn, for what it is worth.

I use Molybdenum Disulfide paste on the splines when I assemble them.

 

yep, dry, when I installed the 4500, I left the rear seal out to lube the power sleeve cavity trans side, you could do the same tcase side, seal the adapter and leave one of the seals out to allow exposure. mine failed on a summer trip from socal, up in mid british Columbia, fortunately made it home, just before the getrag conversion.

 

Yes it is a 29 spline out of a Getrag truck.

The coupler was dry and had no lubrication whatsoever on it or the shafts.

Looking around I think I can get all the parts.

I am wondering what type of factory clip of grommet was used on the transfer case shifter rod. I cant find a pic or anything of it.

 

I use a spring clip from a Hurst shifter. Its a little smaller than the original clip. But it can be found at anyplace that calls itself a speed shop.