Replace transfer case 88 Dodge 350

Paul in MN · Apr 14, 2020

The 88 Dodge is my older farm truck, but used for snowplowing mostly. It has the heavy duty NP 205 transfer case married to the back of the MOPAR 727 automatic tranny. The transfer case sounds like it is cracking walnut shells and maybe sending some of the pieces through the gears. I have the same setup on an 86 Dodge with a rebuilt transfer case. So, I want to remove the 205 from the 86 and put it into the 88. This would not be challenging to me if the transfer case was divorced from the tranny, but I have never done this with the married combination. I do have a tranny jack. Can I unbolt the T case from the back of the tranny, or do I need to remove the tranny and T case together and then split them apart?

Thanks for sharing your experiences with solving this problem.

Paul in MN

Dennis Minn · Apr 14, 2020

Paul,

I have pulled the transfer case from many chevy, but only one dodge. My friend had a torqueflight, and let me say this, be ready for the heft of a 205.

Also, there is a couple of seals and a very important o ring, if I remember correctly. The seals keep the transmission fluid separate from gar lube, but there was an small oring, about an in or so in diameter that really made a difference.

My advice is aged, however, the weight of that t-case was memorable.

As far as I know, the t-case can be pulled sepperate from the transmission. I will call my buddy, it was his truck, and he has a better memort than I.

D.

Paul in MN · Apr 14, 2020

Dennis,

Thanks for your input. In my older IH PUs, they all had divorced NP 205 T cases, and I still have 4 of them. they are a darn heavy unit, but I think my son and I can handle it with the HD tranny jack I have. But the seals is something I had no clue about. I do have the factory service manual, so I'd better study that carefully.

Thanks!

Paul in MN

JDEM · Apr 14, 2020

I'd make sure the transfercase will fit from the other truck. I know with Chevy, that transfercase in a 1/2 ton has different splines then the same model transfercase in a 3/4 or 1 ton. I don't know how if works with Mopar. But yes, you can just unbolt the case and remove it without taking out the trans. I had a 205 in my 1992 Dodge W250 and had it out. Dodge later switched to the all-aluminum 208 in many of the trucks and some people prefer them due to better gear-reduction in low-range.

Hobo,NC · Apr 14, 2020

I never split them in the vehicle unless I have to I do have a lift when I split them I roll it to the rear and hang the transfer case from the rear bumper it makes it a one man job coming apart and going back together...

I have several jacks if need be make brackets ( I should already have them in my Ho-Made tool box) to bolt the TC to a jack to remove it ( Its not Hard) then use another jack to remove the trans...

If you use your head you can make it a one man job with out a fight...

JDEM · Apr 14, 2020

I am curious. I did not know the HD 205 was used in gas trucks for those years. Standard 205 has 23 splined coupler where it joins the transmission. HD 205 has a 29 spline coupler and usually found on diesel Dodge pickups.

Paul in MN · Apr 14, 2020

JDEM,

You just taught me something! When I wrote my post, I did not know there was a difference. I had just assumed that all NP 205's were a heavy duty T.C. because they are an extremely heavy unit (cast iron case). Both of my Dodge trucks (86 - 250 and 88 - 350) are gas engine 360's 4 X 4 trucks. Unfortunately the 86 has much more of a rust problem so I decided it is the donor.

Do you know if there is any external identification on the 205 so that I can be sure it is compatible with the T.C. on the 88 truck?

Thanks for making me a bit wiser.

Paul in MN

Paul in MN · Apr 14, 2020

HOBO,

I don't have a lift so I'll be crawling around under that rusty bugger. Because the T.C. sits at an angle, I think you are right in advising me to make a fixture to bolt to the tranny jack which will adequately support the T.C. I know the jack has some angle adjustment, but I doubt it has enough to accommodate the necessary angle especially for the installation. Thanks for your response.

Paul in MN

Hobo,NC · Apr 14, 2020

Yep I am sure you understand... If I were to yank it all I adapt the jack to the rear transmission support and maybe catch part of the trans oil pan... Out it comes...

4play · Apr 14, 2020

All 205's mated to 727's were the same regardless of gas or diesel. The only 205 that was different was the Diesel/manual trans combo, that also started in 1989 too. You can swap them directly without a worry about fit.

shinnery · Apr 15, 2020

My 1974 Dodge W100 has a divorced NP205. Two more U-Joints to replace.

Paul in MN · Apr 15, 2020

Thank You Sir!

Paul in MN

Replace transfer case 88 Dodge 350

Paul in MN

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