So I dont know what the part is called or how to accurately describe it. On the top of the transfer case where the linkage rod comes from the shifter, it attaches to a flat plate which in turn attaches to the transfer case in I believe 2 different locations. When I had my pre safety inspection for Maryland they noted that it had "excessive wear/play", and that it may be the cause of my near impossible ability to shift out of 4h to 2h. I got under the truck and took a look for myself, and I can see the fitting from the linkage to shifter and its cotter pin, and the two fittings and cotter pins connected to the transfer case. when I try to move the linkage for play I get next to no movement, but when I try to move the plate itself, it moves 3/16" to 5/16" in any lateral direction. I have no idea what this is suppose to be like, or what this plate is called, or how to properly diagnose it. I would imagine, the play could be wear on the individual linkage fittings as well. Does anyone have some knowledge or experience they can share with how to properly diagnose this, as well as what the plate is called and where to buy one if it is bad?

 

Normally, any np205 is hard to shift out of 4wd once the hubs are locked in and tires have made a couple turns. Its the nature of this type of all-gear (no chain) tcase.

You may be dealing with a shop that doesnt understand these things.

 

what about when shifting the transfer case there is no distinguishable feeling between. Neutral and 2h? Well except when it doesn't move afterwards.

 

I think you and the shop are unused the shifting an NP-205.
Sometimes is shifts in smoothly and it is hard to tell. Other times it feels stuck where it is.

If the truck has not had 4x4 used often it can be very stiff.

I am not sure you have a problem that needs much fixing. Lubricating up the pivot points and using it a bunch might make it smoother.
Driving the truck forward and backwards with the steering wheel straight can also help a lot getting it out of 4x4.

 

the best way to get a 205 out of 4x4H to 2wheel drive is to put pressure on the shifter lever towards N and back-up slowly (if you were going forward when you stopped) when the pressure on the gears inside the transfer case loosen up the shifter will easily slide to where you want it to go.

 

The np205 has two shift rails with detents. The ends of the rails poke out of the case, and whatever handle arrangement is attached (Ford, Chev, Dodge, IH).

The internal detent system gives the feel of the 4 positions. The link bar between them stages the two shift rails in the right sequence.

www.offroaddesign.com/tech/offroad-design-transfer-cases-knowledge/offroad-design-np-205-technical-information

 

I'd be surprised if any place understood anything mechanically operated anymore!!!

Ah, The Good Ol' Days...

I find my 205 shifts better (OUT of 4X4) when the tranny is in neutral and the truck is still rolling slightly.

 

My 5 speed shifted a lot easier than the automatic. The problem with automatics is even in neutral, things are still turning unlike a manual. Everything stops when you push in the clutch. On my 92, getting it in or out of 4 high is easy. 4 low is another story. I found the best way is to unlock the hubs, roll it both directions, put it back in park, then shift to high range. And the relock my hubs.

 

I have had a bunch of auto and manual Dodge trucks with NP-205 over the years. I have had auto and manuals that shift harder or easier than other with the same transmission choice..
Take Vern's old '92 W250 for example, it shifts up and down through the T-case about as easy as the Getrag does. Nice and smoothly.

Also realize that during the '89-'93 Dodge Cummins truck run they have two shifter patterns for the NP-205. One is the Z-gated shifted I typically find starting sometime in '91 and running till '93. The straight shifter pattern I find on the earlier '89-'90 trucks

 

That's really interesting. I never knew there was a "Z" pattern. My '92 (auto) & dad's '93 (Getrag) both have the straight shift.

 

The shifter **** pattern even differs to show you how to use it.

 

Wonder what determined which truck got what? Availability during production runs? Different plants received different NPs?

 

The jog in the gate really has nothing to do with the np205 itself. It only affects the motion of the lever.

The plate has 2 slots in it. Is it possible one is used for the manual trans, and the other for the automatic?
https://www.dieseltruckresource.com/...9/#post2355780

 

So from reading the other thread, it looks like KRB and his dad have the later gated shifter, judging from his post in '09...like I usually find on the'92-'93s

 

So, is the "Z" you talk about just the little "dogleg" then? The '93, '92 and '77 205 shifter is exactly the same. Not a full straight pull exactly, just a little nudge to the side. Or maybe I need to crawl under and look closer at the differences between the 90s and the later 70s. In my mind they shift the same...