New Process NP205

The Dodge and GM versions had identical bolt patterns - and 8 bolt pattern for 1971 - 1985 units, and a 6 bolt pattern for later cases. GM models used a 27 spline input when mated to the TH350, and a 32 spline input behind the SM465 manual transmission. Dodge cases were typically 23 spline male input, which required a special sleeve to connect the transmission output shaft to the transfer case input shaft. In diesel applications, the Dodge NP205 had a 29 spline input, which is exclusive to the GETRAG 5 speed manual transmission. Ford used an NP205 with a 6 bolt pattern. They also commonly used a divorced case, which used 1310 series input and front output yokes, and a 1330 series rear output yoke.

It is common to see NP203/NP205 "doublers", which is quite literally a NP203 mated to a NP205. More specifically, the process mounts the range box (not the entire transfer case) of a NP203 to the input side of a NP205, using machined adapters to mate the parts securely. This accomplishes many things - first and foremost, it allows for up to a 3.94 to 1 reduction (2.01 for the NP203 x 1.96 for the NP205, often advertised as a nominal 4:1) with low range engaged in both transfer cases, effectively doubling the gear reduction of a standard NP205 transfer case. Furthermore, it eliminates the potentially problematic and less favorable chain drive system of the NP203. Doubling the two cases require only using the NP203's helical geared reduction box, NOT the entire drive system. Doubling the two cases is an affordable technique in order to retain an extremely stout gear train while reaping the benefits of a compound low range setup.

NP205 Specs