25:22 so those washers or whatever they are aren't needed when putting it back together with the stock full time differential? Or did you do some kind of measurement and determine that your particular application didn't need them? If so, how do you determine if you need them, and how many you need? Never done this before, complete start to finish videos of rebuilding the 203 are non existent, this is the closest one I've been able to find. Thanks for the upload.
does anyone know where the rectangle foam pad thing with the hole in the middle go? Mine fell out during disassembly and i don't remember where it came from.
Holly smokes lol that what mine was doing in my np208 in my Chevy, I though I broke it and almost bought 900$ reman one, thank you so much for posting, now to the next problem with this case, no sync ring or three tabs on the gear, wasn’t there before hope it will work, just have to stop to engage the 4x4 no shift while driving
Very nice video. I was happy to see you convert it back to full time. I did the same thing to mine years ago and they definitely are nicer as full time. I kept good records of fuel consumption before and after and there was zero difference.
@@derekdrivesdodge I'm working on an NP203/NP205 6x6 transfer case. It will use the range box from the 203 mated to the 205. The input shaft of the 205 with be modified. I will use the intermediate 203 shaft and differential parts on the upper rear output. I will move the original 205 output to the lower side. The 205 gear will be driven by the upper chain shaft. It will take some custom machine work. I don't have a Dodge 203 yet so watching your video made things much more clear.
I'm in the process of rebuilding my NP203 and your video is by far the most complete and informative. I think my case is missing the oil trough. Do you have any info on how it mounts? I might try to fabricate one. It just looks like a U shaped piece of sheetmetal.
Hey, glad you liked the vid. I’m not professional for sure but it seems like a few people are finding it handy! I am not sure which trough you are referring to though.
@@derekdrivesdodge BJs off road has them manufactured by a shop and sells them on their website. They are pricy but the only place you'll find new ones.
Honestly have no idea. I know that the input and shafts will have different spline counts so those wouldn’t cross. Subsequently the yokes should be different, otherwise internally it’s plausible that many of the parts could be similar. Guess I’ll have to get one and find out…
Thanks for the video. Have a spare case and going to rebuild it just for fun and to have it ready to go. Definately will use the video to do it. Thanks
Hi do you know if the input bearing and the output bearing can be replaced without disassemble the whole t-case? I think my bearings are already worn out Thanks in advance!
I mean I’m not saying it’s impossible, but I don’t think I’d waste my time trying… you’d have to remove the whole T-Case from the vehicle to do the input anyway, so for the time it would take to overhaul…
Hello, ok well i see you did good job getting 1st gear back on that shaft with those lil clips... my problem is im taking that gear off the shaft and its not very easy at all.. in fact 1 clip broke tryn to get it out... im not sure if your supposed to bang on that gear or what to get 1st gear off the main shaft becauseof the clips its stuck. im gonna try agian in the morning.. hopefully i can get another spring like i said ones broke now... thanks any help is much appreciated .... my 1st time with one of these... everything looks good so far just altta bearing noise while drivin...anyways in a 3/4 1990 Dodge truck... 😁
So the gear is seized onto the shaft and doesn’t move at all?!? In either direction?!? I’ve yet to come across that problem! Terrible luck! They’ve all just slid right off and I’m looking for the springs because they just fell off! I’ve not had to fight with one yet but I would feel comfortable applying some force to that gear, I don’t think you could hurt the shaft or the gear at all… rubber mallet or piece of wood to strike on… The springs aren’t doing anything to keep the gear on the shaft, maybe the clearances are excessive and your trying to take it off slightly crooked and it’s binding? 🤷🏼♂️ I have disassembled one that was in service with only one spring and another that was run with none. I’ve heard they aren’t overly important to have but don’t have personal experience with that.
@@derekdrivesdodge hello agian, well my gear actually will move back n forth but stops lil shy of coming off that main shaft... ok i will try to hammer it with a rubber mallet or whatever it takes now that i know it does come off that way...i think its going to be a bear though cuz it seems very stubborn anyways definitely appreciate your quick response.. thankyou!!
Sorry, no. Last search I tried produced zero result and if they were avail they would have been 2-3 times the cost of an entire used case so it didn’t seem worth it.
I used a USA Standard Gear kit ZTBK203G. It does not come with the needle bearings for the differential and most thrust bearings/plates. Basically anything that did come with this kit I re-used or replaced with another unit I parted out. The one I was overhauling had the part-time kit installed and I swapped it out with a full-time diff I had from that unit. I didn’t source any other parts from a vendor, just parted out another one for this build.
I have a 1979 Chevy Blazer K5 and it has the NP203 transfer case, I want to change the transfer case oil but I can only see the fill bolt, do you know where the drain bolt is?
There isn’t one on any I’ve seen and the two case halves prevent it all from coming out any one spot. The inspection plate cover on the ‘range case’ half can be removed to drain most. The magnet is right there too so that’s a good time to check that out. Those bolts pass through the case so removing just the lowest one will drain that half. Then the bolts that hold the retaining plate for the chain sprocket also pass through the case so the lowest one can be removed to drain the second case further. You won’t get it all, but if you let it sit a while you get enough out. Hope this helps.
Thank you for that. I have 1 that I have to disassemble and weld a crack in the case. Then I am going to rebuild it and adapt it to a Dana 18 for my Jeep. Anything I can find to help me with this is great.
25:22 so those washers or whatever they are aren't needed when putting it back together with the stock full time differential? Or did you do some kind of measurement and determine that your particular application didn't need them? If so, how do you determine if you need them, and how many you need? Never done this before, complete start to finish videos of rebuilding the 203 are non existent, this is the closest one I've been able to find. Thanks for the upload.
does anyone know where the rectangle foam pad thing with the hole in the middle go? Mine fell out during disassembly and i don't remember where it came from.
Almost done putting mine together watching this video. Question, what were the torque specs when bolting it together? Thanks
Just went through my np203 but my shift linkage rod is extremely stiff, can’t even move it back and forth with a wrench. Any ideas?
Holly smokes lol that what mine was doing in my np208 in my Chevy, I though I broke it and almost bought 900$ reman one, thank you so much for posting, now to the next problem with this case, no sync ring or three tabs on the gear, wasn’t there before hope it will work, just have to stop to engage the 4x4 no shift while driving
Thankyou! tore mine apart 2 years ago and for multiple reasons couldn't get back to it. This is extremely helpfull !
just did mine with your video. Thanks!!
Glad it helped!
Man thanks a ton for this video. That was great!
Glad you liked it!
Hey Derek what brand/part# are those snap ring pliers? thanks
They are an OTC Horseshoe Snap Ring Pliers 714
Great video!!!
Need a disassembly version
That seems to be the east part 😆
Right
Thank you 🙏
Your video is gold man! One question though, on the output tail housing how do you keep the oil pump seal from popping out during installation?
Great video , the tip with the wood was great!
BRAVO. this is beyond helpful.
How do you clean it all up like that? Do you media blast it and paint? Also, what rebuild kit do you use?
I had it media blasted and the prime/paint like you would an engine. The kit I used was a USA Standard Gear kit ZTBK203G
Very nice video. I was happy to see you convert it back to full time. I did the same thing to mine years ago and they definitely are nicer as full time. I kept good records of fuel consumption before and after and there was zero difference.
Very nice video showing all the important aspects of reassembly.
Thanks!
@@derekdrivesdodge I'm working on an NP203/NP205 6x6 transfer case. It will use the range box from the 203 mated to the 205. The input shaft of the 205 with be modified. I will use the intermediate 203 shaft and differential parts on the upper rear output. I will move the original 205 output to the lower side. The 205 gear will be driven by the upper chain shaft. It will take some custom machine work. I don't have a Dodge 203 yet so watching your video made things much more clear.
@@derekdrivesdodge does the range box share oil with the chain section on the original 203?
Like the video most detailed one but out of curiosity are you putting any gasket sealant on your paper gaskets and if so what are you using?
Just an oil is fine. I’ve been using an assembly lube with success but no sealant is required.
Thank you!!!
You’re welcome!
Gracias, no podía dejar de agradecerte está enseñanza
You’re welcome
I'm in the process of rebuilding my NP203 and your video is by far the most complete and informative. I think my case is missing the oil trough. Do you have any info on how it mounts? I might try to fabricate one. It just looks like a U shaped piece of sheetmetal.
Hey, glad you liked the vid. I’m not professional for sure but it seems like a few people are finding it handy! I am not sure which trough you are referring to though.
What about chain stretch? Does anyone produce 2” 203 chain? Great video man
I’ve just aways re-used the chain. I have not had any success finding new chains.
@@derekdrivesdodge BJs off road has them manufactured by a shop and sells them on their website. They are pricy but the only place you'll find new ones.
Any idea how much different the NP203 is for a GM application?
Honestly have no idea. I know that the input and shafts will have different spline counts so those wouldn’t cross. Subsequently the yokes should be different, otherwise internally it’s plausible that many of the parts could be similar. Guess I’ll have to get one and find out…
very helpful! thank you so much!
Thanks for the video. Have a spare case and going to rebuild it just for fun and to have it ready to go. Definately will use the video to do it. Thanks
Hi do you know if the input bearing and the output bearing can be replaced without disassemble the whole t-case? I think my bearings are already worn out Thanks in advance!
I mean I’m not saying it’s impossible, but I don’t think I’d waste my time trying… you’d have to remove the whole T-Case from the vehicle to do the input anyway, so for the time it would take to overhaul…
Hello, ok well i see you did good job getting 1st gear back on that shaft with those lil clips... my problem is im taking that gear off the shaft and its not very easy at all.. in fact 1 clip broke tryn to get it out... im not sure if your supposed to bang on that gear or what to get 1st gear off the main shaft becauseof the clips its stuck. im gonna try agian in the morning.. hopefully i can get another spring like i said ones broke now... thanks any help is much appreciated .... my 1st time with one of these... everything looks good so far just altta bearing noise while drivin...anyways in a 3/4 1990 Dodge truck... 😁
So the gear is seized onto the shaft and doesn’t move at all?!? In either direction?!? I’ve yet to come across that problem! Terrible luck! They’ve all just slid right off and I’m looking for the springs because they just fell off! I’ve not had to fight with one yet but I would feel comfortable applying some force to that gear, I don’t think you could hurt the shaft or the gear at all… rubber mallet or piece of wood to strike on… The springs aren’t doing anything to keep the gear on the shaft, maybe the clearances are excessive and your trying to take it off slightly crooked and it’s binding? 🤷🏼♂️ I have disassembled one that was in service with only one spring and another that was run with none. I’ve heard they aren’t overly important to have but don’t have personal experience with that.
@@derekdrivesdodge hello agian, well my gear actually will move back n forth but stops lil shy of coming off that main shaft... ok i will try to hammer it with a rubber mallet or whatever it takes now that i know it does come off that way...i think its going to be a bear though cuz it seems very stubborn anyways definitely appreciate your quick response.. thankyou!!
@@frankrizzo3922 just make sure there isn’t like a retaining clip on the shaft itself or something weird like that…
Thank you so much! Saved me some frustration and made reassembly much easier!
Your welcome! Glad it helped!
Do you have a recommendation on sourcing a new chain?
Sorry, no. Last search I tried produced zero result and if they were avail they would have been 2-3 times the cost of an entire used case so it didn’t seem worth it.
See previous comment reply…
Just started making them in the past few years: www.bjsoffroad.com/NP-203-Transfer-Case-Chain-ONLY-Made-in-USA-HV-005_p_2108.html
What was the vendor you used for the rebuild kit and any other misc. Parts like a gear or shaft in need of replacing?
I used a USA Standard Gear kit ZTBK203G. It does not come with the needle bearings for the differential and most thrust bearings/plates. Basically anything that did come with this kit I re-used or replaced with another unit I parted out. The one I was overhauling had the part-time kit installed and I swapped it out with a full-time diff I had from that unit. I didn’t source any other parts from a vendor, just parted out another one for this build.
I have a 1979 Chevy Blazer K5 and it has the NP203 transfer case, I want to change the transfer case oil but I can only see the fill bolt, do you know where the drain bolt is?
There isn’t one on any I’ve seen and the two case halves prevent it all from coming out any one spot. The inspection plate cover on the ‘range case’ half can be removed to drain most. The magnet is right there too so that’s a good time to check that out. Those bolts pass through the case so removing just the lowest one will drain that half. Then the bolts that hold the retaining plate for the chain sprocket also pass through the case so the lowest one can be removed to drain the second case further. You won’t get it all, but if you let it sit a while you get enough out. Hope this helps.
@@derekdrivesdodge thank you so much, and is the proper fluid 10w30 motor oil?
Just a standard 30 weight motor oil is fine.
@@alannguyen5050 The GM book and Haynes books say use automatic transmission fluid for the NP203 transfer case
@@clintpike9983 Intresting, when I drained it, the fluid looked exactly like motor oil.
Thank you for that. I have 1 that I have to disassemble and weld a crack in the case. Then I am going to rebuild it and adapt it to a Dana 18 for my Jeep. Anything I can find to help me with this is great.
Thanks! I would recommend the kit from Novak Conversions, it seems to be of better quality and most complete in my experience.