NP205 Transfer Case Review – 10K Miles in our DIY Expedition Truck
10k mile Review - NP205 Transfer Case
When designing our expedition truck, four-wheel drive was a must-have. We wanted the capability to explore remote, backcountry roads and the confidence to drive safely on snow-covered highways. After researching dozens of options, we chose a New Process NP205 transfer case—a legendary, all-gear unit known for durability in demanding conditions.
Our unit is over 50 years old, but after a complete rebuild with high-quality, USA-made bearings, gaskets, and seals, we expected it to handle anything we could throw at it. Now, with 10,000 miles on the build, this is our NP205 review—covering what works, what we’d change, and how it fits into a modern overland build.
Why the NP205 Was the Right Choice for Our Expedition Truck
We needed a transfer case that could handle the 12,700-pound (5760kg) weight of our fully loaded rig while being simple to service in the field. The NP205’s proven track record, gear-driven design, and huge aftermarket support made it the clear winner.
Rock-Solid Reliability
In over 10,000 miles, the NP205 has delivered consistent, trouble-free performance. Considering its age and unknown prior service life, the reliability so far has been exactly as expected, exceptional. For overland travel, where breakdowns in remote areas can have serious consequences, this peace of mind is invaluable.
Twin Stick Mod for 2WD Low Range
One of the most practical upgrades we made was the twin stick modification. This allows us to run 2WD low range without unlocking and re-locking the front hubs. On technical dirt roads or when maneuvering slowly in camp, this flexibility saves time and effort. Switching from 2WD low to 4WD low is as simple as moving a lever—no need to get out of the cab.
Future Upgrade Potential
The NP205 platform offers excellent long-term upgrade options. We’re already considering:
Adding a doubler (an additional gear reduction) for extreme low-range gearing.
Installing a PTO-driven air compressor for faster tire inflation.
This adaptability ensures the NP205 can evolve with our build over time.
Where the NP205 Setup Could Be Improved
While the NP205 itself has been excellent, our specific installation has a few drawbacks—mainly due to packaging and gearing.
Heavy Shifting Effort
Because of our crew cab layout, we use 12-foot shift cables routed forward before looping back to the transfer case. While functional, the long cable runs create resistance, making some shifts stiff. Occasionally, we have to roll the truck slightly to help the gears mesh. A redesigned linkage with more mechanical leverage could improve shifting without adding electronic complexity.
Low Range Could Be Lower
The NP205’s 1.96:1 low range is strong but not deep by modern standards. With a high-revving gas engine, highway-oriented transmission, tall tires, and the lowest practical axle gears, we sometimes wish for more crawl capability. A doubler would provide that extra reduction for technical rock crawling or deep sand.
Final Verdict – NP205 in Overland & Expedition Use
The NP205 transfer case continues to prove itself as one of the most reliable, serviceable, and adaptable choices for overland and expedition travel. Its simple, gear-driven design, massive bearings, and rebuild-friendly nature make it ideal for moving heavy rigs through challenging terrain.
If we were starting this build over, we would choose the NP205 again without hesitation. For anyone building a 4x4 intended for long-distance, off-grid travel, it remains a top choice.
Over the coming years, we plan to push this drivetrain into more extreme environments and will share a long-term update once the miles—and challenges—start adding up.
