On a NP205 I would like to know what people have broken... Its an all gear tcase so I KNOW its very strong... but what parts have people broken.... so basicly If i came accross a t-case in a junkyard and they want a fortune for the whole thing but i can get some parts off of it for less what should I pick up?

If you look around you should find a hole case for under $75...I have found them for $40. hell just last week I got two 203`s and a 3/4 chev 44 front for $60... Who sead crack heads are a bad thang ? you just have to find one that has parts :flipoff2:

P.S. divorced cases are normaly the cheapest.

Originally posted by d.d.machine


P.S. divorced cases are normaly the cheapest.

I find it the other way around .... I have a hell of a time finding Divorced cases....

ive got an divoreced 205 from an old ford .
ya want it ?:flipoff2:

Originally posted by dangerranger33
On a NP205 I would like to know what people have broken...

that's just great!!

i wanna see or hear the guy who broke an NP-205.

i've never seen one of those M/F broken.

oh yea, they'll break your back but THEY will never break:smokin:

well from all my searching the only thing that breaks on a 205 is the adapter :eek: so i think youll be safe there dr33 .unless that hood scoop of yours is covering a blown 460 or something
:D
http://www.pirate4x4.com/forum/attachment.php?s=&postid=469100

they (Jess at HighAngle) sells an upgraded front output shaft, so thats gotta be one of the only weakER points. never heard of anyone breakin one tho'

Ive got one that has the front output busted off! It was a case that came originally behind a 1Ton Chevy With a Th400. :D Ill post pics in a few.

Originally posted by Alaska Offroad
Ive got one that has the front output busted off! It was a case that came originally behind a 1Ton Chevy With a Th400. :D Ill post pics in a few.

That's the first I've ever heard of anyone breaking an NP 205. Most people break everything but the 205. When I was still working for a shop, there was a guy that used to come in with an '89 Dodge Cummins 1 Ton that he used for towing. He fried the tranny, then came back later with a broken bellhousing, then with sheared ring gear bolts on the rear D70. Never an issue with the 205. He asked my boss if he thought the power stroke would be more reliable. My boss told him, "I think you need to be looking for a Kenworth." :eek:

Wow!, somebody broke a front output!!! They are supposed to be only marginally weaker than the rear output, as they are 30 spline, the rear is 32 spline. I have heard of the older 10 spline input shafts breaking when put behind a klune-V or doubler box, that is why it is recommended to upgrade to a 32 spline female input from a TH400 case. As for the coupler's always breaking, i was told that they are designed to do that from the factory to save tranny and tcase parts...

laters-

Originally posted by elf_cruiser
Wow!, somebody broke a front output!!! They are supposed to be only marginally weaker than the rear output, as they are 30 spline, the rear is 32 spline.


what do you mean by 30 splines?

the inner dia. is the same with all of them - 1.5".

it's just the spline count that changes.

for example - the input for a TH-400 is 32 splines
while the input for a TH-350 is 31 splines.
i know there are more spline counts for input/output shafts.

it does'nt really make a difference strengthwise.

NP-205 cases are as far as i know one of the most popular and widely manufactured for all the major makers in U.S.A. it probably has the most configurations and spline counts than any other t-case model.

in any case - it's the best case!!!:):)

http://www.alaskaoffroad.com/images/Tech/Tcase/205carnage2.JPG

http://www.alaskaoffroad.com/images/Tech/Tcase/205carnage.JPG

Th-400 Np-205 Broken front output 32 Spline. (could have been 30 Spline, I cant remember whatcame stock) Took out the shifter, broke the transmission and put a large dent in the frame! :D

The number of splines does make a difference in strength. Even if the shaft is the same dia. more splines will have more surface are to take the load. Also the cross section will be larger. (kind of like Fine thread bolts are stronger than coarse). :D

http://www.alaskaoffroad.com/images/Tech/205frontoutputs.jpg

Note the larger dia of splines. The upper is the one I am running in my Doubler and the lower is the one that came out of a 1/2 Ton case.

Might as well put this here as well....

http://www.alaskaoffroad.com/images/Tech/205inputshafts.jpg

Here you can see four of the different kinds of 205 input shafts. One the very left is the Th-350 version. The next one over is the 32 spline Th-400 version. Then the SM-465 shaft and coupling sleeve. And on the right is the 31 spline Ford input shaft that I used with my WMS Dual T-case setup. :usa:

I think what he was trying to say is that there is not much difference between the 31 spline or the 32 spline. On the other hand those 2 pictured would make a difference!!! :D

Originally posted by MattS
I think what he was trying to say is that there is not much difference between the 31 spline or the 32 spline. On the other hand those 2 pictured would make a difference!!! :D

right on man.

not much difference between the 30, 31, & 32 spline shafts.

BUT, a big difference between those and the OLD 10 spline count. i think this one was out of production about 20 years ago.

Okay, I've seen a 205 break.

83 Suburban, 454, t-350, heavily loaded going up Vail pass, hear a loud bang and no go. Shift to low range, go fine. Go back to high and bang, jump outa gear. Stick it back in low range and turn 5k rpms home (never thought ya could do 60 mph in low).

When we got home we swapped in another case. Have yet to tear it apart to see what broke (to busy with other projects).

So what was it?

(I don't know squat about 205s, all my cases are D20s)

Th-400 Np-205 Broken front output 32 Spline. (could have been 30 Spline, I cant remember whatcame stock) Took out the shifter, broke the transmission and put a large dent in the frame!

That would be a 30spline front output, exactly what i have... Looks like somebody was putting some serious weight on the front end. I wanna know what kind of front axle held up while that shaft broke?? Or did somebody come down hard on a rock, and shear it that a way...?


Laters-

So basicly if i'm understanding this right... with an NP205 .... I need NO spare parts... what about the ouput yokes? do they break?

Call High Angle Driveline for jokes, and/or CV stuff. Jesse uses brand new Spicer components, and they are tuff. I run a 1350 CV to 1410, and i'd say it's as strong as the output shaft on the case.

I wanna know what kind of front axle held up while that shaft broke??

Dana 60:D

Happened while plowing snow:eek:

Originally posted by the frog


what do you mean by 30 splines?

the inner dia. is the same with all of them - 1.5".

it's just the spline count that changes.

for example - the input for a TH-400 is 32 splines
while the input for a TH-350 is 31 splines.
:):)

actually the input to the transmission on a th350 is 27 spline. A ford 205 is 31 spline input to tranny and th400 205 is 32 splien to back of tranny..chevy205's had 10 spline front outputs or 30 spline outputs(front driveshaft output) and 32 spline tailshaft..ford and dodge had 32 spline front output(to driveshaft) on some models.just some info..:D

Originally posted by dangerranger33
On a NP205 I would like to know what people have broken... Its an all gear tcase so I KNOW its very strong... but what parts have people broken.... so basicly If i came accross a t-case in a junkyard and they want a fortune for the whole thing but i can get some parts off of it for less what should I pick up?

I have never known a yard that would sell parts of a t-case. Its all or none. Usually you just buy the whole damn thing for about $75 and call it good. This shiat just keeps on comin!:rolleyes:

Well you all convinced me that I need to change out my NP203 to a NP205 just happen to have one too;) ;)

Dont swap it! Just take the back off and add a 205 to that! Its Cake:D

I am getting one rebuilt right now. May be I will post the pictures of the broken pieces from the inside.

i broke 2 10 spline inputs and 1 front 30 spline output and broke the iderler gear in half at diffrent times i also have broken 2 465 output shafts to but i have never broken a rockwell.;)

The toughest 205 would be the TH400 32 spline input (from the Tranny) with a 32 spline output (to the rear driveshaft) and a 32 spline front output (front Driveshaft)

Chevy 205's had 30 spline front outputs (FDS) that are weaker and smaller than Ford 32 spline front outputs (FDS)

Plus, the Chevy 205 has a 3R flange adaptor, which is about the same strength as a 1330 or 1350.

If you change over to the 32 spline Ford Front output (FDS), you can then attach a 1410 yoke.

Changing the front Driveshaft output shaft is about a 10 minute job.

Early Dodge cummins have a 32 spline female input like the TH400 cases and a 32 spline front output.

The Divorced 205s would probably be the strongest with a rolled 32 spline male input shaft, and 32 spline front output.

number of splines does not mean dick in actual strength of a shaft all by itself. It has to do with the manufacturing process to make those splines and the material.

When chevy did the 10 spline coupler back in the day, it was the strongest alternative, because they did not have the technology to roll splines at the time.

I run a turbo 400 205 in my truck... 32 spline output front and back... 1410 yoke in the back, and flange in the front. The driving flange I run is the same style that will bolt up to a ford 1350 CV, however, I took 2 broken Dana 60 axles and cut the yokes off. I welded one to the drive shaft and one to the driven flange (the one that bolts up to the transfer case flange), both front and back. My front shaft is at 31 degrees at rest and nothing else would come close unless I went to Jesse. The Dana 60 axle yokes use 1480 joints and have a maximum operating angle of 48 degrees or so. No vibration, and more angle than I'll ever be able to throw at it. I used a 3" .250 shaft, long slip stub and 1350 axle yokes on a Dana 60. I can change the shaft out and replace it in about 5 minutes.... Bottom line- 32 Spline front and rear outputs on the t-case, TH 400 32 spline input and flanges... Nothing should ever break and maintenance is a breeze....

I thought I was the only one to cut and weld 60 yolks to gain high angle. I called every were looking for some way to get the 45 deg. of angle I needed out of the center joint on my ford TTB beam setup and noone had a clue on how to help me. So finally I had a stub shaft made to bolt a four bolt flang on next to the dif going to the pass side , then I made a flange and welded a 60 yolk to it and then a 60 yolk to a driveshaft slip that hapened to fit my stock axle, stuck it all together and it works great.
Off the topic but I had to throw it in there after reading MR4WD post.

as said before the only things I have seen break on (or around) a 205 are the adapter between it and a 350, and the front output shaft

My brother bought an 1980 3/4 ton Chevy that had the Output Shaft from the 400 and the Input Gear on the 205 stripped. Farmer said he was backing out of the driveway and put it into gear. Who know what else he did prior to that.

Originally posted by Diesel Junkie
Early Dodge cummins have a 32 spline female input like the TH400 cases and a 32 spline front output.



My 93 Dodge Cummins Had a 23 spline male input in its 205 with the sleeve like Chevys use to connect their 205 to the tranny shaft.. I broke the input gear and the intermediate gear.. cost too much($900) to get another from the salvage yards here so I now have a year on my 208 in there..

i have a friend that has broken the 10 spline front outputs before going to the 32 spline front output. I also have a friend that broke a rear output but it was a 4 speed truck and it was on the street so i am sure he was doing a holeshot or something. I managed to bust low range in my 205 at the beach and it just so happens the same weekend i broke the 60 r@p in front and had to cruise around in the sand dunes in 2 wd high range, A real common breakage piece also is the sleeves and input and adapters on the 4 speed, and th350 205s. Seen alot of those break