Dan the Gear Man® Tech Note 1:
With the original Getrag G360, the Splined Coupler is not bathed in oil, so spline wear due to direct metal to metal contact is very common. If your coupler splines are worn, there is a good chance the matching shaft spline is also worn. Installing a new Coupler on a worn shaft will only be a short-term fix as the worn shaft splines will quickly wreck the coupler splines.
Dan the Gear Man® Tech Note 2:
Grease the shaft and coupler splines on your new coupler before installation in a truck with the original G360 5 speed manual transmission.
Dan the Gear Man® Tech Note 3:
If you are adapting a 29 spline output Dodge NV4500 or NV5600 to use with a 29 spline NP205, you need to have the 4-1/2" wide cast iron factory round 6 bolt x Figure 8/8 bolt transfer case adapter. You also need to remove the transmission output seal and add an extra quart or so of oil to the transmission to fill the adapter space. Install a new TK10517 Double Lip, Double Spring Transfer Case Input Seal in the back of the factory adapter along with new TK10519 and TK10529 Gaskets. TK10517 Seals oil both ways so it acts as both the transmission output seal and transfer case input seal. You must also apply threadlocker to 8 bolts that attach the adapter to the transfer case.
Dan the Gear Man Tech® Note 4:
Need Tech Help on rebuilding your NP205? Get my TM2000 New Process NP205 Transfer Case Service Manual. A Complete NP205 shop Manual with over 375 color photographs is your indispensable NP205 resource for Repair Procedures and Parts Identification. Complete coverage of Disassembly, Inspection, and Reassembly Procedures. Also, Shop Notes, Tool Recommendations, Complete Parts Guide, and full color Exploded Views, including Right Drop and Left Drop Models, plus GM Specific Parts. Covers New Process NP205 Transfer Cases found in Chevrolet, Dodge, Ford, GMC, and International Harvester (IHC) 4x4 vehicles from 1969-1993.
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Dan the Gear Man® Tech Note 5:
Matching Parts for QU10528 29 Spline Coupler:
QU50305 Getrag 29 Spline 4x4 Mainshaft
TK10566 29 Spline Dodge NP205 Input Shaft
TK2001 29 Spine NP205 Input Shaft Kit
TK10519 6 Bolt Round Transmission to Adapter Gasket
TK10529 8 Bolt Figure-8 Adapter to Transfer Case Gasket
QU50287 Output Seal for Getrag G360 4x4 Transmission
TK10517 Double Lip, Double Spring Transfer Case Input Seal
TK2002 Input Shaft Gasket and Seal Kit
TM2000 NP205 Service Manual
TM2002 NP205 Exploded Views and Parts Guide