Tearing apart np205 for input shaft swap...questions

[CaptainInsano]

What size socket does it require to remove the rear output nut?

What size socket does it require to remove the intermediate shaft nut?

How difficult is twin sticking it...and is it even worth it?

[crewcabroller]

http://www.offroad-tech.com/tech/twinstick205/

[Ryan B.]

I *think* 1-1/8" and 1-5/16", not positive though. I can really check tommorow if you need.

[CaptainInsano]

I *think* 1-1/8" and 1-5/16", not positive though. I can really check tommorow if you need.

1-1/8 worked for the front output. The intermediate and rear output are bigger. I measured them and they seem either 1-1/4 or 1-5/16". I guess I'll just buy both sockets.

One of my shift rails won't come out either. I tapped out the roll pins holding the shift forks on already. :unsure:

I've decided I'm not doing the twin stick right now because of cost. I don't see the need to justify the cost. My luck I'll screw it up anyways.

[Nosmog73]

I *think* 1-1/8" and 1-5/16", not positive though. I can really check tommorow if you need.

1-1/8 worked for the front output. The intermediate and rear output are bigger. I measured them and they seem either 1-1/4 or 1-5/16". I guess I'll just buy both sockets.

One of my shift rails won't come out either. I tapped out the roll pins holding the shift forks on already. :unsure:

I've decided I'm not doing the twin stick right now because of cost. I don't see the need to justify the cost. My luck I'll screw it up anyways.

IIRC it is 1 5/16" I had to look all over for a thin wall socket that size because 3/4" drive was to thick to fit in the yoke..And I wasnt going to grind a good socket to fit

[barbastard]

When my doubler got installed I opted out of twin sticking my 205 as well. I just couldn't justify the need for it against the money it was going to cost me. Even if I did all the work myself...I couldn't really justify the time it would take. I mean really.....how often would you use it?? Just get the fucker done and slap it in there....it's time to go wheeling!!! :beer:

[CaptainInsano]

When my doubler got installed I opted out of twin sticking my 205 as well. I just couldn't justify the need for it against the money it was going to cost me. Even if I did all the work myself...I couldn't really justify the time it would take. I mean really.....how often would you use it?? Just get the fucker done and slap it in there....it's time to go wheeling!!! :beer:

Exactly. I'll most likely not even relocate the np205 shifter. Going full blown redneck style. I might actually be able to get this thing done in time for that Presidents day run.

[sr175]

mine was 1 5/16 but has to be thin wall. I had to take mine to the local drive shaft shop and they had a socket that was milled down just for this purpose. I tried grinding......... it was futal :(

[CaptainInsano]

mine was 1 5/16 but has to be thin wall. I had to take mine to the local drive shaft shop and they had a socket that was milled down just for this purpose. I tried grinding......... it was futal :(

My yoke has a good amount of space, I think I'll be alright. However I know what ya mean, I have two np203 yokes I need to get off and that is the problem. Need to buy a cheapo socket and grind it.

[sr175]

mine was 1 5/16 but has to be thin wall. I had to take mine to the local drive shaft shop and they had a socket that was milled down just for this purpose. I tried grinding......... it was futal :(

My yoke has a good amount of space, I think I'll be alright. However I know what ya mean, I have two np203 yokes I need to get off and that is the problem. Need to buy a cheapo socket and grind it.

mine is all basic 1310 and that is why it is tight. Just like what will be on the 203 you have.

[CaptainInsano]

http://www.offroad-tech.com/tech/twinstick205/

Cool write up on the twin sticking setup. Can that Big Alternator be modified to work on a '78 rig? Have ot change the pull to a v-pulley, not sure on the connections. Would be sweet to have that much power.

[CaptainInsano]

Got the NP205 all torn apart, ready for machining. Guess I should take some pics of this whole process for the WMS doubler.

Trying to figure out how I'm gonna mount it all. I'm thinkin of lifting all the drivetrain up and running completely flat on the bottom, and running solid engine mounts. I think if everything is solid mount it should be ok. The weak spot is definitely the sm465 bellhousing...aluminum.

3/8" plate steel should be beefy enough yeah? Do I need that thick?

If I ever finish this project it will be a fucking miracle. I still have a shitload to do. :crazy:

[Ryan B.]

So was it 1-5/16" for the rear output and idler shaft? :beer: :chaz:

Let me know where you're getting your case bored for the larger input bearing.. and how much.. I have a bare case i need to do the same. If they're setting up the machine to bore one, they might as well do a couple. :unsure:
I know scott 4x4high has a friend that can do it for $40.

[4X4HIGH]

At least that's what he charged for the last one i had him do for me. :thumb:

[CaptainInsano]

At least that's what he charged for the last one i had him do for me. :thumb:

I'll be calling ya tomorrow. :thumb:

[4X4HIGH]

Ok. Hey Ryan, get me your case if you want it done also. Like you said, might as well do a couple if he is going to make a set-up to do it. I do need the bearing you are going to use though, from the both of you. Just because it is the same bearing doesn't mean they will be the exact same size.

[Ryan B.]

Yup. I figured i better get that 32 spline input and bearing before i have the case bored. :unsure: I'll probably order one tommorow.

[CaptainInsano]

Got my case back from Scott already! Thanks dude! I'll be putting that sucker back together this weekend hopefully.

[4X4HIGH]

Something i noticed but forgot to mention to you but i'm sure you already seen it. Why was the inside of the case worn at the front output shaft area? Did you find anything bad inside that would explain that wear?

[CaptainInsano]

Something i noticed but forgot to mention to you but i'm sure you already seen it. Why was the inside of the case worn at the front output shaft area? Did you find anything bad inside that would explain that wear?

That is the shaft that had the bearing that was falling apart. I'll check it all twice when I put it back together. My gear still looks ok. I bet that happened when my t-case fell out at HighLakes. :uh oh: Blue Locktite'n everything this go round.

[CaptainInsano]

Got all my parts, assembling today. Anyone got torque specs for the tcase? Especially the intermediate shaft nut and yoke nuts :flipoff2:

Thanks!

[4X4HIGH]

Got all my parts, assembling today. Anyone got torque specs for the tcase? Especially the intermediate shaft nut and yoke nuts :flipoff2:

Thanks!

Idler gear shaft is 90-130 ft. lbs.
yokes are 90-130 ft. lbs. as well.

[CaptainInsano]

Got all my parts, assembling today. Anyone got torque specs for the tcase? Especially the intermediate shaft nut and yoke nuts :flipoff2:

Thanks!

Idler gear shaft is 90-130 ft. lbs.
yokes are 90-130 ft. lbs. as well.

thanks Scott