The NP205: A Builder’s Deep Dive into the Iron Legend

Looking back at our past projects, there’s one piece of hardware that consistently stands out as the backbone of a solid rig: the New Process 205. I’ve spent a lot of hours with this 140lb lump of cast iron on my workbench, and even though this video is from a little while back, the lessons I learned while tearing it down still apply to every build I touch today. For the guys looking to build something that won’t leave them stranded, the 205 is the ultimate “Victory” insurance policy.

The “Pain”: Respecting the Iron

I won’t sugarcoat it—wrenching on a 205 is a workout.

• The Weight: At roughly 140 lbs, it’s not something you want to drop on your foot. It’s a cast iron housing stuffed with massive steel gears. Compare that to a modern aluminum NP231 that weighs maybe 80 lbs, and you realize you’re trading lightness for pure, unadulterated strength.
• The Input Headache: Not all 205s are created equal. In the shop, I had to deal with a version that came from a manual transmission, which meant it had the small, weaker input shaft. To make it survive what I had planned, I had to swap in the beefy 32-spline input from a TH400 automatic. It’s a bit of a process, but building it right the first time beats fixing it on the trail every time.

The “Victory”: Why We Still Choose It

The reason I’m such a fan of the 205 is simple: it’s gear-driven. No chains to stretch or snap, just massive steel gears meshing together.

• The Doubler Strategy: A stock 2:1 low range is a bit high for serious crawling. But the beauty of the 205 is its compatibility. By prepping this case to mate with an NP203 range box, you create a “Doubler” that gives you a 4:1 crawl ratio. That’s where the magic happens.
• Twin-Stick Potential: I’ve always been fascinated by the twin-stick setup. By modifying the shift rails, you can achieve “Front Dig” (front-wheel drive only), allowing you to pivot the rig in tight spots. It’s a technical challenge to set up, but once you’re on the rocks, it’s a total game-changer.

Josh’s Shop Note:

If you’re sitting on the sidelines because you’re intimidated by an old transfer case, don’t be. It’s just heavy metal and a bit of logic. Every stuck bolt is just a puzzle waiting for a solution. Grab a wrench, stay positive, and remember that the “Pain” of the shop is what makes the “Victory” on the trail so sweet.

Wheel it, Wreck it, Wrench it, Repeat!