NP205 shifting not working right - rebuilt incorrectly?

[qwertyd10n]

Hi there,

Following directions from another member's post (http://www.fordification.com/forum/view ... =9&t=50999), I have managed to swap the NP435 (2wd version) tranny and Dana 21 TC originally in my '66 F100 4x4 for a much stronger NP435 (4wd version)/NP205 combo.

I got oil in everything today and before connecting driveshafts, I thought I should try everything out as both the new transmission and transfer case were units I bought and didn't know too much history on them.

Well, the good news is that the transmission seems to be working just fine. Now for the not good news (I won't say bad quite yet). The NP205 I bought was apparently rebuilt just before I bought it and not knowing that much about them, I didn't know what to look for - but it seemed to look alright. I had the inspection plate off and all the gears look good... there doesn't seem to be any bearing play issues, etc.

So here's what seems to be happening:
- pushed by transfer case shift lever as far forward as I could, hoping it was in 4L. Put the transmission in gear and only the front yoke turned.
- pulled the shift lever back one notch (or at least I think it was one), which should have put the transfer case in Neutral. However, the front yoke still turned - nothing out of the rear yoke.
- pulled the shift lever back another notch, which should have been 2H. The front yoke still turned and got nothing out of the rear again.
- pulled the shift lever back as far as it would go now - should be 4H - and both yokes turned. But then it seemed like the "top" shift rail popped a little and the rear stopped again.

I didn't hear any grinding or unruly sounds at all... just didn't seem like the gear for the rear yoke was engaging and the front yoke was always engaged. Could the shift rails have been installed improperly? Or is there something else wrong with the TC I bought?

If this is a small fix with the shift rails, my next questions will be around how difficult it is to fix? Do I have to tear down the entire TC?

Cheers,
Dion

[fordman]

sounds like the shift mechinsim in the transfer case is messed up. came apart. wasnt put back together right. who knows. you'll probably have to take it apart and see for sure. before you do thought you could try unhooking the shift linkage and see if the t case will shift and work without the shifter.