Anyone attempted repair on their NP205? Mine is making a very unhappy noise under (any) load in every gear, and it only goes away if I put her in 4-HI with the hubs locked..

 

Just rebuilt mine. Input shaft, rear output shaft and complete kit. Ran about 700.00 for the parts at driveline.com. Not too tough a job.

If yours is making noise in 2wd it may only need bearings for the intermediate shaft. They come in the kit, that was about $270.00 I think.

 

What happened to it? Was it making noise?

 

I had a bad vibration. Bad enough that once it started the only way to make it stop was to stop the truck and start out again. Made the truck un-drivable.

 

I am getting a clunk clunk clunk. I jammed on it one day and it started clunking.... I feel sick! I am pretty sure it's the t-case though.

 

Doesn't sound good. I assume you've checked the usual suspects outside the case, u-joints, CV center joint, rear output yoke nut... I don't know what outside of bearings would cause a clunk unless you managed to break a gear or engagement ring. Seems unlikely though, those parts are BIG. Is it possible the linkage hung up and it's partly in or between gears?

It's not a huge job to get it out and apart to inspect. Then order what you need if you can have the truck down for a few days. There are several good rebuild guides on the web if you search for them.

 

Now I'm not sure if it's the T-Case or the trans. When I put side pressure on the shifter in 5th the noise get's louder. I can't tell if it's the output shaft bearing on the trans or input bearing on the T-Case. I don't have a spare vehicle right now, and it hasn't been above freezing in weeks .
I gotta find an old Duster or something to spell Big Red.

p.s. this is the coldest winter we have had in a long time. I'm ready for some global warming!

 

Well, something let go today, and the truck was sounding like Ber-roid was hitting my drive train with a metal bar. I limped to my friends shop and we put it up on jack stands, turned out I lost the ring and pinion, not the t-case or trans after all. So much for my diagnostic skills. Before it totally grenaded I could put side pressure on the shifter then the noise would get really loud, so I started thinking it might be the output bearing on the trans....
We pulled the rear driveshaft and I drove it home Toronado style (loads or torque steer).
Anyway, I am greatly releaved that it wasn't a gear box after all. If the carrier is destroyed I'm going for a Detroit Locker this time. I'm sick of clutches burning up my dif....
Gotta go rob a bank now, see yall....