Need NP-205 transfer case expert

[powerstoke64]

Hey guys need a expert on the np 205 transfer case. I rebuilt my NP205 t-case myself and seems I ran into a slight problem. Anyway Im about done with it or so I thought. My question is I put my rear output shaft in my t-case and everything spins freely like its suppose too, however when i put the housing over it and tighten it down its locks the the shaft right up. The rear output shaft is down as far as it goes. Even when I lay the housing on it, it spins freely but as soon as I tighten it down it locks up.

 

[m78]

What parts did you replace with new ?

 

[DNFXDLI]

You might want to have a read of this article:

http://stuff.is-a-geek.net/OnlineDocs/Vehicles/NP205/www.okcnetworks.com/bronco/205/np1.html

Also....there is a procedure in the manual subforum here...I've had one apart years ago and I can't recall specifics.

 

[powerstoke64]

Heres are some pictures of what I mean seems like my input shaft sits up to high but I replaced the roller bearings in it and made sure everything looked right.

housing

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shaft

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Inside

 

[powerstoke64]

Like I said I can't get the housing down on it without it locking up the shaft seems like the shaft it sitting up higher I can't get it to go down any more.

 

[m78]

First thing I would check is to see if the roller bearing on the other side isn't too wide

 

[BigNate]

PS64 where are you at?

If you let loose of this tidbit of info and someone is close by they'll likely be willing to drop by and take a look.

I don't know what clearances are supposed to be but it sounds like a bearing isn't seated correctly or there is some clearance not being measured correctly. Having not had one completely apart I recommend trying to assemble with one shaft out, see if it will turn, then try the other until you know which is causing the binding issue. If the both spin until they are both installed then the clearance between them may be an issue in some way. I'd look at bearing instalation before everything else though.

 

[dustybumpers]

In pic # 2, your gear lash is out a bit, you may be putting it in a bind. Could be you have to turn it a bit to seat things as you get the case closed