Hey guys I've searched every where for any kind of an answer. Heres the deal right from the start. I bought an 86 chevy with a turbo 400 mated to a 205 in it. 60 front 14 bolt rear. The first couple of times I drove it the t-case sounded rather noisey on decel. I searched and talked to a few people and they suggested a shift fork problem. I bought a shift fork and installed it. I don't think I even need to say it but of course no fix. So I bought another 205 and started swapping parts. no change. I bought a bearing kit and installed. The noise got worse and now the stupid thing is popping out of gear. Now I'm not an expert on 205 transfer cases but I am a master certified tech so I'm pretty sure I have everything together right. You and I both know there is always that chance. I have not changed out the input shaft or the coupler ring. Any ideas would be greatly appreciated. I'm not afraid to throw parts at this thing I'm just tired of throwing money at it. By the time I get this stupid thing fixed I could have bought a rebuilt unit. Thanks again for any information.

Hey I am currently going through the same issue with the front out put on my 205 except mine is completly rebuilt with all new parts to include shafts and rails. So here are the options....

1. The shift fork is instaled backwards so how to tell is the part that slides over the shift rail there is a long side and a short side (not the fork that comes down its the cylindricle part on the front and back of the fork) So long story short the long side should be towards the front of the case (front of the vehicle) and this is true on the front and rear output.

2. another option is that the shift rail is machined wrong and the detents are not in the proper place, or the springs that hold the ball in the detent are to weak to hold it in place.

3. The last option and this is the one I am personally dealing with is that the case its self has a flaw, now i know this sounds crazy but I have been dealing with this for a while with mine and this is all me and stephen at offroad design can fugure. So the remedy to is simply a custom shift rail which is quite simple weld in the current detents put it all together make sure the slider gear is in the currect place for hi low nutr mark it and the grind them out.

I hope this helps if you need pictures or anything like that let me know ill be glad to share what i have learned the hard way. I hope my verbage makes sence

Josh

what about the engaugement ring/slip collar. it take times the wear that the fork does.

i HIGHLY doubt that the detents are wrong.

how did the idler bearings look?
the little loose rollers in the input shaft?
did you repreload the ider bearing when you put the new ones in?
rear out put bearing?

In my opinion too much free play in the idler gear will cause it to be noisy. ALWAYS remove the idler and clean out the oil passages, this is where crap builds up.

I always use new shiftrails when rebuilding a case. If you think the modified detents are wrong and have twin stick, leave the interlock pills out. Only do this if you make the front output rail neutral notch bigger. (only do this mod if you know how to shift a t-case properly)

If the alignment teeth are worn down, get new replacement gears and shift collars. Sharp teeth shift alot nicer then worn teeth.

i agree with Corey on this one... there should be no more than .008" of play in the idler gear, front to back. if there is more, y ou have bearing issues. and then you have shim issues.