how hard is it to rebuild a 205 - what might be needed from a shop

[AuroraGirl]

So I decided this winter i want to try my hand at t case rebuild. plenty of videos and my shop manual to help if i need it, and i have 2 of them.
how heavy is it? Like, So I can make a bench HD enough for it
how hard is it? Ive rebuilt a few minor mechanical things before, like small carbs and smartphones, computers, ps pump, etc. not many.
How do i determine if I need a shop to do any work or am SOL or need a part
I have 2 205, 1 with a slip front, 1 with a slip rear. Should I make a fixed/fixed? I have all the driveshafts already that will fit my truck

i would consider the np208 but its on my truck now, if it were off i would tossup.
Also, if i successfully do the NP205, i would like to try the sm465 but im not gonna push it.


edit: one t case is from 77, one is from 80

 

[Bextreme04]

The videos I've seen make it look super easy. Its all gears and bearings, so any serious damage should be fairly obvious once apart. I would just buy a quality rebuild kit, tear it down completely, clean and inspect everything, and throw it back together. It never hurts to scrub the outside and throw a quick coat of enamel on it at the same time either.

If I remember correctly the NP205 is a heavy B in the ~200lb range. I'll be rebuilding my 80' 205 this winter when the old drivetrain comes out before I put the new 454 in.

If the 80' 205 came off a TH400, it wont work on the SM465. They have a completely different output.

 

[Snoots]

Dry, with no shifter ~ 140 lbs.

 

[bucket]

Dry, with no shifter ~ 140 lbs.

I wasn't sure they even weigh that much. Carrying them around, they don't feel much heavier than a 208.

 

[Rusty Nail]

LoL?

 

[AuroraGirl]

I wasn't sure they even weigh that much. Carrying them around, they don't feel much heavier than a 208.

im not saying i cant carry it... but i havent tried and attached to the adapter it was a mfer to wiggle around as it was lol

 

[PrairieDrifter]

I wasn't sure they even weigh that much. Carrying them around, they don't feel much heavier than a 208.

Easily 150, np208 doesn't compare to the weight of a 205. Sm465 was 180 complete weight I believe.

 

[PrairieDrifter]

You need big bearing pullers, I don't think it's a typical claw puller either I could be wrong though, and a press for sure. Think there may be one other special tool for something.

Check out GebBuilt on YouTube he has a full rebuild on the sm465 and np205 and he did an excellent job! He was going by the book in front of him as well.

 

[AuroraGirl]

would a small harbor freight press work? I was looking to buy their small end one. i have a press that is about twice my height and also about 10 feet long and over 500 pounds, 800 maybe easily. but that ram is overkill for anything i will ever do lol

 

[Curt]

I can carry the 205 off the ground,but not the SM 465.It has to be hip level.That thing is nasty.

There’s a decent video by Jeb on YouTube taking down and rebuilding his 205.He also did the shift rails and twin stick.

 

[Curt]

The harbor freight press will be fine.I haven’t found anything on a square that the 12 ton press wouldn’t do.Used it to rebuild a Dana 60 and 14 bolt.Cost a 100$ on sale.

 

[ali_c20]

When you rebuild it you could convert it to twin stick.
Mine is twin stick, shifts really nice and smooth.

https://www.offroaddesign.com/gm-np205-twin-stick-shifter.html
http://www-rockbottom4x4-com.4165476.n2.nabble.com/Twin-Stick-that-NP205-here-s-how-td5806734.html

 

[AuroraGirl]

When you rebuild it you could convert it to twin stick.
Mine is twin stick, shifts really nice and smooth.

https://www.offroaddesign.com/gm-np205-twin-stick-shifter.html
http://www-rockbottom4x4-com.4165476.n2.nabble.com/Twin-Stick-that-NP205-here-s-how-td5806734.html

is that a lot for a novice like me?

 

[AuroraGirl]

The videos I've seen make it look super easy. Its all gears and bearings, so any serious damage should be fairly obvious once apart. I would just buy a quality rebuild kit, tear it down completely, clean and inspect everything, and throw it back together. It never hurts to scrub the outside and throw a quick coat of enamel on it at the same time either.

If I remember correctly the NP205 is a heavy B in the ~200lb range. I'll be rebuilding my 80' 205 this winter when the old drivetrain comes out before I put the new 454 in.

If the 80' 205 came off a TH400, it wont work on the SM465. They have a completely different output.

they both mated to sm465 i should have clarified, they only swapped which one has slip yoke on whichh side. drop is the same.
My 1980 it is on the front, my 1977 frame it was on the back. oddly, the frame had a slip driveshaft on both despite having a slip joint

 

[AKguy]

These two gems have been invaluable during my project and both hold 350 pounds. The exam table is electric and runs down to about 14”. The lift is manual hydraulic and the supports legs can be moved closer/further apart with a lever.

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