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The New Process NP205 Transfer Case was the last all gear drive transfer case offered by U.S. vehicle manufacturers for one ton and lighter 4x4 trucks. Because the basic layout dates back to WWII, rebuilding the NP205 is not a job that requires a Rocket Scientist, but there are enough quirks in the disassembly and reassembly to make having our full color, step-by-step TM2000 NP205 Transfer Case Shop Manual a necessity to keep your blood pressure down! To help keep your parts in order, both our TM2000 Manual and TM2002 Parts Guide include 5 pages of color Exploded Views for both Direct and Remote Mount NP205 Transfer Cases. Both publications are available in print or electronic versions. See our quad4x4.com NP205 web page for a complete listing of available NP205 Parts and Tools.
The Syracuse, New York built, New Procees NP205 part time, gear drive transfer cases were original equipment in
many 1969-1991 Chevy/GMC, 1969-1993 Dodge, 1974-1979 Ford, and
1969-1974 International 4x4 vehicles.
| TM2000 New Process NP205 Transfer Case Shop Manual | ||||||
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| TM2000 NP205 Transfer Case Technical Service Manual Complete NP205 shop Manual with over 375 color photographs is your indispensable NP205 resource for Repair Procedures and Parts Identification. Complete coverage of Disassembly, Inspection, and Reassembly Procedures. Also, Shop Notes, Tool Recommendations, Complete Parts Guide, and full color Exploded Views, including Right Drop and Left Drop Models, plus GM Specific Parts. Covers New Process NP205 Transfer Cases found in Chevrolet, Dodge, Ford, GMC, and International Harvester (IHC) 4x4 vehicles from 1969-1993. Roberts, MT, 2006. 84 pages of technical content, 8½" x 11". Available in printed or electronic version: Printed Hard Copy (TM2000P 8-1/2"x11") Compact Disc (TM2000CD PDF format), Instant Download to Your Computer (TM2000DL PDF format) Click on the thumbnails below to see a larger jpeg image of selected pages. TM2000 Includes the entire content of TM2002 NP205 Exploded Views and Parts Guide sold below. |
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| Printed Hard Copy | TM2000P Printed Hard Copy NP205 Shop Manual High Quality, full color printing on 8-1/2" wide x 11" high paper. Has plastic covers and will open flat so you can have the Manual right next to you as you rebuild your NP205 Transfer Case! !PLEASE READ BEFORE ORDERING: Copyright Terms of Use $40.95 or Save $1 by purchasing Online for only $39.95! |
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| Download | TM2000DL Internet Download Electronic PDF file NP205 Shop Manual Download direct to your computer now! Adobe PDF format. Requires Adobe Reader 7.0 or higher preferred. Enabled for high resolution printing. 21.5 MB !PLEASE READ BEFORE ORDERING: Copyright Terms of Use and Ordering 4x4 Tech Downloads $19.95 |
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| Compact Disc | TM2000CD Electronic PDF file NP205 Shop Manual on Compact Disc Convenient PDF format burned on a CD-R disc. Requires Adobe Reader 7.0 or higher preferred. Enabled for high resolution printing. !PLEASE READ BEFORE ORDERING: Copyright Terms of Use $20.95 or Save $1 by purchasing Online for only $19.95! |
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| TM2002 New Process NP205 Transfer Case Exploded Views and Parts Guide | ||||||
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| TM2002 NP205 Exploded
Views and Parts Guide Fully Illustrated with dozens of crisp color photographs for EASY Parts Identification! This Manual includes 10 page Parts Identification Guide and full color Exploded Views, including Right Drop and Left Drop Models plus GM Specific Parts. Covers New Process NP205 Transfer Cases found in Chevrolet, Dodge, Ford, GMC, and International Harvester (IHC) 4x4 vehicles from 1969 to 1993. Roberts, MT 2006. 18 pages of technical content, 8½" x 11". Available in printed or electronic versions. Printed Hard Copy (TM2002P is 8-1/2"x11") Instant Download to Your Computer (TM2002DL in PDF format) Click on the thumbnails below to see a larger jpeg image of selected pages. The entire content of this Manual is included in the TM2000 NP205 Service Manual sold above. |
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| Printed Hard Copy | TM2002P Printed Hard Copy New Process NP205 Exploded View and Parts Guide High Quality, full color printing on 8-1/2" wide x 11" high paper. Has plastic covers and will open flat so you can have the Manual right next to you as you compare your parts! !PLEASE READ BEFORE ORDERING: Copyright Terms of Use $14.95 or Save $1 by purchasing Online for only $13.95! |
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| Download | TM2002DL Internet Download Electronic PDF file NP205 Exploded Views and Parts Guide |
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| Videos | ||
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| Sorry, No NP205 Videos available at this time | ||
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Chevy and GMC
Links to Our Parts Web Pages for Chevy and GMC Trucks and 4x4's |
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| Axles and Brakes | Clutch and Engine | Driveshafts and General Interest |
Steering and Suspension | Transfer Case |
Transmission | |||
| Axle, Front GM 1991-prior Solid |
Engine Parts, Chevy and GMC |
Driveshaft, GM Front Constant Velocity |
Steering Gear Parts | Transfer Case, Chevy and GMC |
Transmission, Chevy and GMC |
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| Axle, Front GM IFS |
Driveshaft, GM Front Non-CV |
Borg Warner | 4 Speed SM420, SM465 |
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| Axle, Chevy and GMC Rear |
Driveshaft, Chevy and GMC Rear |
Dana 20 | 5 Speed NV4500 |
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| Brake Parts, Chevy and GMC |
GM Index Page | New Process NP203 |
5 Speed NV4500 Kits |
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| Tools, Chevy and GMC |
New Process NP205 Parts |
5 Speed NV4500 Parts |
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| New Process NP208C |
5 Speed NV4500 Small Parts |
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| New Process NP231C |
Transmission, 5 Spd NV4500 Tools |
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| New Process NP241C |
6 Speed GM ZFS6-650 |
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| New Process Other Models |
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| Please keep in mind not all web links are live, as we are still in the process of updating our web pages. | ||||||||
| Quad 4x4 Home Page | ||||||||
Dodge
Links to Our Parts Web Pages for Dodge Trucks and 4x4's |
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| Axles, Brakes, and Steering |
Clutch, Engine and Other |
Driveshafts | General Interest | Transfer Case | Transmission |
| Axle, Front AAM 925 2003-up |
Rear Axle | Driveshaft, Front Dodge 1993 and Prior |
Clutch | Transfer Case, Dodge All Years |
Transmission, Dodge General |
| Dana-Spicer 44 Closed Knuckle 1959-1973 |
Axle, Rear AAM 10.5" 2003-up |
Driveshaft, Front Dodge 1994-2002 |
Cummins Diesel | New Process NP200 and NP201 |
4 Speed to 1993 NP435 and NP445 |
| Dana-Spicer 44 Open Knuckle 1972-1974 |
Axle, Rear AAM 11.5" 2003-up |
Driveshaft, All Dodge 2003-2010 |
Tools, Specific for Dodge |
New Process NP203D Parts |
5 Speed 1989-1993 Getrag G360 |
| Dana-Spicer 44 Live Spindle 1974-1979 |
Axle, Rear Chyrsler 8.25 |
Driveshaft, Rear Dodge 1993 and Prior |
New Process NP205 Parts |
5 Speed 1993-2004 NV4500 |
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| Dana-Spicer 44 1980-1984 |
Axle Rear, Chyrsler 9.25 |
Driveshaft, Rear Dodge 1994-2002 |
New Process NP208D Parts 1980-1987 |
5 Speed NV4500 Kits |
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| Dana-Spicer 44 1985-1993 |
Dana-Spicer 60 1961-1971 |
Common Front Axle | New Process NP231D Parts |
5 Speed NV4500 Parts |
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| Dana-Spicer 44 Ram 1500 1994-2001 |
Dana-Spicer 60 1972-1979 |
Common Rear Axle | New Process NP231DHD Parts |
5 Speed NV4500 Small Parts |
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| Dana-Spicer 44 Ram 2500 1994-1997 |
Dana-Spicer 60 1980-1993 |
New Process NP241D Parts 1987-1993 |
Transmission, 5 Spd NV4500 Tools |
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| Dana-Spicer 60, 61 1975-1993 |
Dana-Spicer 60 1994-2002 |
New Process NP241DHD Parts 1994-1997 |
NV4500 Rebuild for Dodge |
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| Dana-Spicer 60 Ram 2500-3500 1994-1997 |
Dana 70, 70HD 1957-1971 |
New Process NP241DHD Parts 1998-2002 |
6 Spd
G56 2005-up 2005-up |
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| Dana-Spicer 60 Ram 2500-3500 1998-1999 |
Dana-Spicer 70, 70HD 1972-1979 |
New Process NP241DLD Parts 1994-1997 |
6 Speed 1999-2005 NV5600 Information |
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| Dana-Spicer 60 Ram 2500-3500 2000-2002 |
Dana-Spicer 70, 70HD 1980-1993 |
New Process NP241DLD Parts 1998-2002 |
6 Speed NV5600 Parts |
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| Dana-Spicer 70 Closed Knuckle 1967-1978 |
Dana-Spicer 70 1994-2002 |
New Process NP241D Parts 2002-up |
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| Axle, Dana Front 1994-2002 |
Dana-Spicer 80 1994-2002 |
New Process |
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| Axle, Front Dana 1993 and prior |
Dana-Spicer 111 2008-up |
New Process NP/NV273D Parts 2003-up |
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| Axle Parts, Small for Dana Front Axle |
Axle. Dana Rear 1994-2002 |
Rockwell T223 W600 1974-1978 |
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| Axle, Dana Rear 1993 and prior |
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| Axle Parts, Small for Dana Rear Axle |
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| Please keep in mind not all web links are live, as we are still in the process of updating our web pages. | |||||
| Quad 4x4 Home Page | |||||
Ford
Links to Our Parts Web Pages for Ford Trucks and 4x4's |
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| Axles, Brakes and Steering |
Clutch, Engine, and Other |
Driveshafts | General Interest | Transfer Case | Transmission |
| Dana-Spicer 30 Bronco 1967-1971 |
Corporate 8.8" and Smaller |
Driveshaft, Front 1998 and prior |
Clutch Parts for Ford | Transfer Case, 1998 and prior |
Transmission Ford General |
| Dana-Spicer 44 Closed Knuckle 1959-1975 |
Corporate Ford 9" |
Driveshaft, Front 1500 1994-2001 | Ford Special Tool Page |
1999-up Super Duty and Excursion |
4 Speed BW T98, T18, T19 |
| Dana-Spicer 44 Open Knuckle 1969-1979 |
Corporate Ford 9.75" |
Driveshaft, Front 2500-3500 1994-2002 | Common Front Axle | Borg Warner 1345 |
4 Speed NP435 |
| Dana-Spicer 44 IFS 1980-1983 |
Dana-Spicer 60 1954-1972 |
Driveshaft, Front Super Duty, Excursion |
Common Rear Axle | Borg Warner 1350/1354 |
Transmission, 5 Spd Light Duty |
| Dana-Spicer 44 IFS 1984-1996 |
Dana-Spicer 60 1972-1979 |
Driveshaft, Rear 1998 and prior |
Engine Parts, Diesel or Gas |
F-Seies to 1996 Borg Warner 1356 |
5 Speed ZF42 and ZF47 |
| Dana-Spicer 50 IFS 1980-1982 |
Dana-Spicer 60, 61 1980-1997 |
Driveshaft, Rear Super Duty, Excursion |
F250, F350 1996-1997 Borg Warner 4407 |
ZF 6spd | |
| Dana-Spicer 70 1961-1972 |
Dana-Spicer Model 20 |
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| Dana-Spicer 50 Excursion 2000-2005 |
Dana-Spicer 70 1973-1979 |
Dana-Spicer Model 21 |
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| Dana-Spicer 50 Super Duty 1999-2004 |
Dana-Spicer 70, 70HD 1980-1997 |
Dana-Spicer Model 24 |
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| Dana-Spicer 60 Closed Knuckle 1974-1975 |
Dana-Spicer 80 F-450 1988-2002 |
New Process NP203 Parts |
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Dana-Spicer 60 |
Dana-Spicer 80 F350 DRW 1999-current |
New Process NP205 Parts |
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| Dana-Spicer 60 King Pin Type 1985-1991 |
Dana-Spicer 110 1999-up |
New Process NP208F Parts |
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| Dana-Spicer 60 Ball Joint Type 1992-1997 |
Dana-Spicer 135 |
Transfer Case, 271F, 273F |
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| Dana-Spicer 60 Super Duty F250-F350 1999-2004 |
Axle, Dana Rear |
Rockwell T223 | |||
| Dana-Spicer 60 Super Duty F450-F550 1999-2004 |
Axle Parts, Small for Dana Rear Axle |
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| Dana-Spicer Super 60 Super Duty F250-F350 2005-up |
Sterling 10.25" 1985-1997 |
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| Dana-Spicer Super 60 Super Duty F450-F550 2005-up |
Sterling 10.5" F250, 350 SRW 1999-up |
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| Axle, Front Dana 1997 and Prior |
Axle, Ford Rear 10.25" and 10.5" |
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| Axle, Front Dana 1998-2004 S-Duty |
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| Axle, Front Dana 2005-up Super Duty |
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| Axle Parts, Small for Dana Front Axle |
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| Please keep in mind not all web links are live, as we are still in the process of updating our web pages. | |||||
| Quad 4x4 Home Page | |||||
General Interest
Links to Our Web Pages for General Interest |
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| Company Information |
Online Tech Articles A-M |
Online Tech Articles N-Z |
Other Web Sites | Parts | Parts and Supplies |
| Contact Us | Dana Rear Axle Component Failures | Tech Article Index Page |
4x4 Tech Info Home Page |
Axle Parts, Dana-Spicer Differentials | Apparel, QUAD 4x4 Made in U.S.A. |
| Dan The Gear Man | Dodge 1994-2002 Front Axle PM |
TA: NV4500 Cast Iron Tail Housings | 4x4 Repair Manuals Home Page |
Axle Parts,
Small for Front Axle |
Chemicals |
| Downloads: Ordering Information |
Getrag G360 to NV4500 Conversion |
NV4500 Tranmission Conversion Info |
4x4 Tools Home Page |
Axle Parts, Small for Dana Rear Axle |
Hardware |
| Order and Tax Information |
NV4500 5th Gear Failures and Solutions |
Torque King Home Page |
Differential Parts, Dana-Spicer Axles |
Lubricants | |
| Shop Services, Off Vehicle |
NV4500 Transmission NV4500 FAQ |
New Process NP205 Transfer Case |
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| Shop Services On Vehicle |
Causes of Manual Transmission Failures | NV4500 New Transmissions | |||
| What's New | NV4500 Transmission, NV4500 Kits |
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| NV4500 Transmission Large Parts |
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| NV4500 Transmission Small Parts |
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| Common Front Axle | |||||
| Common Rear Axle | |||||
| Please keep in mind not all web links are live, as we are still in the process of updating our web pages. | |||||
| Quad 4x4 Home Page | |||||
IHC and Jeep
Links to Our Parts Web Pages for IHC and Jeep 4x4's |
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| Axles, Brakes and Steering |
Clutch, Engine, and Other |
Driveshafts | General Interest | Transfer Case | Transmission |
| Axle, IHC and Jeep Front |
Driveshaft, Jeep | IHC/Jeep Index Page | Transfer Case, IHC and Jeep |
Tranmission, Jeep | |
| Axle Parts, Small for Solid Front Axle |
International and Jeep Special Tools |
Transfer Case, Jeep |
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| Axle, Jeep Rear | Common Front Axle | Transfer Case, IHC and Jeep Dana 18 |
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| Axle Parts, Small for Dana Rear Axle |
Common Rear Axle | Transfer Case, IHC and Jeep Dana 20 |
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| Brake Parts | Transfer Case, Jeep Dana 300 |
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| Transfer Case, IHC and Jeep NP200, NP201 |
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| Transfer Case, IHC NP205 |
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| Transfer Case, Jeep NP208 Parts |
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| Transfer Case, Jeep NP231J |
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| Transfer Case Jeep, Other New Process |
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| Please keep in mind not all web links are live, as we are still in the process of updating our web pages. | |||||
| Quad 4x4 Home Page | |||||
Manuals and Videos
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| Component Specific Appliction |
Chevy/GMC | Dodge | Ford | IHC/Jeep | Universal |
| NP205 Transfer Case | Manual Index Page | ||||
| NV4500 Transmission | Downloads: Ordering Information |
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| Copyright Info | |||||
| Please keep in mind not all web links are live, as we are still in the process of updating our web pages. | |||||
| Quad 4x4 Home Page | |||||
Tools
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|---|---|---|---|---|---|
| Tools by Tool Application A-F |
Tools by Tool Application G-M |
Tools by Tool Application N-S |
Tools by Tool Application T-Z |
Tools Universal Application |
Tools, by Vehicle Make |
| Ball Joint Tools | Front Axle Tools | NV4500 Special Tool Page |
4x4 Tools, General | Chevy and GMC Special Tool Page |
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| Bearing Cup Installers | U-Joint | Dodge Special Tool Page |
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| Dana Axle | Tools, Specific for Ford | ||||
| Driveshaft Tools | International and Jeep Special Tool Page |
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| Front Axle Shaft Seal Installation Tools | |||||
| Please keep in mind not all web links are live, as we are still in the process of updating our web pages. | |||||
| Quad 4x4 Home Page | |||||