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post #1 of (permalink) Old 08-08-2000, 07:29 PM
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Rebuild your 203?

Have any of you ever rebuilt your own 203 transfer case? If you have, how bad was it? cost? does it work better and not jump out of gear, how was the slop after you were done. I am thinking of rebuilding mine, and any info would be greatly appreciated. Thank you in advance.

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post #2 of (permalink) Old 08-09-2000, 12:04 AM
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Re: Rebuild your 203?

Today has been a $h!ty day. I think my Transfer Case is going out or is out or almost out. 96 1500 Z71. What transfer case is this..... And what is the deal with rebuilding them. LIke rmarkin
was asking is it worth it? How hard is it and how much does it cost.? Please Help!!!

BigBlue Z71 [img]/wwwthreads_images/icons/cool.gif[/img] [img]/wwwthreads_images/icons/cool.gif[/img]
post #3 of (permalink) Old 08-09-2000, 02:39 AM
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Re: Rebuild your 203?

rmarkin, if your main problem is that it's just jumping out of gear, then you probably just need to adjust the linkage. Somebody here can tell you how to do it, personally I've never adjusted one, but several of my friends have had to to get them to stop jumping out of gear.

<font color=green>Evan</font color=green>[img]/wwwthreads_images/icons/crazy.gif[/img]

<font color=red>- Contagious Off-Road -</font color=red>

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post #4 of (permalink) Old 08-09-2000, 09:03 AM
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Re: Rebuild your 203?

To adjust the linkage, put the t-case shifter in neutral. Crawl under the truck and locate a small hole in the shifter housing just above the shifter ears. With the shifter in neutral the hole in the housing will line up with the holes in each shifter ear. Use a drill bit the size of the hole and run it through the housing and shifter ears. Adjust the linkage. You will probably find that the linkage has too much slop in it.

I rebuilt my NP 203 for about $150.00. New chain, gasket kit, and new bearing assembly behind the plantery gear. If you are considering a part time kit, install it during the rebuild. However, you can install the part time kit with the case in the truck. Biggest job is getting the case out and in. It is very heavy and at an angle where the weight is not equally distributed. I build a jig and bolted it to may floor jacket. A Haynes mannual does a pretty job explaining the shifter adjustment and tear down of the case. Hope this helps.
Bob W

post #5 of (permalink) Old 08-09-2000, 09:14 PM
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Re: Rebuild your 203?

I agree with Shaggy and Bob. WATCH OUT on dropping and installing that monster, It was a ^&%()*^%)$ to get back in my rig. AFTER we installed it, I got a jack adapter- Oh well hindsight is 20/20 [img]/wwwthreads_images/icons/laugh.gif[/img]. Take your time on the rebuild, those little loose needle bearings like to fall all over the place, and hide, never to be found again- Dohhh.

<font color=blue>Maverick</font color=blue> <font color=red>CH 4 or 35</font color=red> [img]/wwwthreads_images/icons/smile.gif[/img]
post #6 of (permalink) Old 08-10-2000, 10:07 AM
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Re: Rebuild your 203?

I was going to change the fluid on my 203 this weekend when I discovered it had gear oil in it.
Can I just drain this out and put the 10w30 in it?
Or is there something I have to do first?
Any ideas? I need to do this so I can drive the truck home finally.


[img]/wwwthreads_images/icons/crazy.gif[/img]<font color=blue>78 Chevy 3/4 in the rough</font color=blue>
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