ok rebuilt the 205 in my K5 about 9 months ago, truck hasn't really been driven but 100 miles since. Transfer case won't shift on it's own into N or 4 Low, shifter just won't push the shift rail in...2 Hi and 4 Hi work great..

Took a small Ball peen and tapped the rail and got it back into 4 low tonight and I could shift between the different gears with the shift lever..kinda

shifting was increadably hard and there wasn't a Neutral position.. what's parts fawked do ya think? :confused:

Sounds like a problem with the shift rails.. The first thing to check it that the 2wheel/4wheel shift rod is in correctly not up side down.. If that rod is in upside down it will allow you to shift between 2 and 4 wheel drive but the interlock pins will be held in preventing the other shifting rod from moving..

ok this is gonna sound like a fawkin newbie question but it's been about a year since I tore into this case. can I check that rail somehow without taking the case apart? or pulling it from the truck?

You will have to pull it because you will need to remove the shaft to look at it.. you should be able to remove the case from the truck pull it apart put it back together and reinstall it in a day..

oh boy, that sounds like fun:D
if ya ask me nicely i might actually help ya do it...or atleast stand there and point..

standing around and drinking peoples beer is what usually happens from what I"ve seen. Soon as I get a set of seals I'll pull it. I'll let ya know. Nice rig BTW, it was definetly sweet