AA Intermediate Shaft

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   Have any of you guys ever had experience with a New Process Gear model 205 transfer case? (Ford, 1973-79, Chevy mid 60's-81, Dodge mid 60's-80)

It has tapered roller bearings on the intermediate gear.

It has been 25 years since I did repair work on this model of transfer case but as I recall there wasn't a thrust washer used in this gear box design. Maybe the same principles don't apply to the AA box. I am not familiar with the design.

Edited by SE Kansas 46 CJ-2A - 26 Aug. 2020 at 3:06pm

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SE Kansas 46 CJ-2A Members Profile Send Private Message Find Members Posts Add to Buddy List Member Sponsor Member x 3 Joined: 22 Jan. 2016 Location: S.E. Kansas Status: Offline Points: 3192	Post Options Post Reply Quote SE Kansas 46 CJ-2A Report Post Thanks(0) Quote Reply Posted: 26 Aug. 2020 at 3:04pm
	Have any of you guys ever had experience with a New Process Gear model 205 transfer case? (Ford, 1973-79, Chevy mid 60's-81, Dodge mid 60's-80) It has tapered roller bearings on the intermediate gear. It has been 25 years since I did repair work on this model of transfer case but as I recall there wasn't a thrust washer used in this gear box design. Maybe the same principles don't apply to the AA box. I am not familiar with the design. Edited by SE Kansas 46 CJ-2A - 26 Aug. 2020 at 3:06pm
	46 CJ-2A #64462 "Ol' Red" (bought April 1969)(second owner)(12 V, 11" brakes, M-38 frame, MD Juan tub) U.S. Coast Guard Chief Petty Officer(ret.) U.S. Army Vietnam veteran and damned proud of it.

unclemoak Members Profile Send Private Message Find Members Posts Add to Buddy List Member Joined: 06 Oct. 2018 Location: Englewood, CO Status: Offline Points: 352	Post Options Post Reply Quote unclemoak Report Post Thanks(0) Quote Reply Posted: 26 Aug. 2020 at 5:05pm
	Here are a few pictures of the gears. As a refresher, here's a picture of the kit. The distance between the back of the gear and the back of the case is fixed by the shaft. The front gap is the variable one that's set by the the collar that slides over the front of the shaft and is tightened by the nut on the front of the case.

jpet Members Profile Send Private Message Find Members Posts Add to Buddy List Moderator Group Sponsor Member x 5 Joined: 30 Apr. 2008 Location: Ramsey, IL Status: Offline Points: 11174	Post Options Post Reply Quote jpet Report Post Thanks(0) Quote Reply Posted: 26 Aug. 2020 at 6:15pm
	How much bigger is the flange if the inner bearing over the bushing? Normally the thrust is forward here which would pull on the shaft and back of the case even though the front of the case is stronger. If there was a thrust washer in here that is the same thickness of the gap between the case and the race, both the front and the rear would be resisting the forward thrust. .... not saying it’s necessary. I’m just talking.
	CJ2A #29110 "General Willys" MB #204827 "BAM BAM" "We do what we can, and we try what we can't"

Slowtwitch Members Profile Send Private Message Find Members Posts Add to Buddy List Member Joined: 23 Jan. 2023 Location: Montana Status: Offline Points: 89	Post Options Post Reply Quote Slowtwitch Report Post Thanks(0) Quote Reply Posted: 01 May 2023 at 3:55pm
	I am getting ready to install this kit. Any pearls of wisdom on bearing setup/adjustment? The directions provided by AA are pretty vague. What has worked for guys long term?

Slowtwitch Members Profile Send Private Message Find Members Posts Add to Buddy List Member Joined: 23 Jan. 2023 Location: Montana Status: Offline Points: 89	Post Options Post Reply Quote Slowtwitch Report Post Thanks(0) Quote Reply Posted: 07 May 2023 at 2:23pm
	Alright, the crickets have spoken. I got this from Herm.. after reading the instructions, I summarily tossed them in the bin. I also dispensed with the castle nut and two thinner jamb nuts and bought a thin nyloc nut to sneak up on the adjustment. I put a couple dots of threadlocker on the outter lip for added lock and also as witness marks to make note of any nut movement. Seems like a really nice upgrade.. too bad it will be difficult to discern any difference in noise, etc as we are changing a number of things simultaneously.