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  1. Chris64

    NP203 removal and rebuild

    I don't really understand what you're telling me. I know later transfer cases had supports, as this should too based on it's weight, but it bolts into a 1/2" thick iron plate so as long as I'm not jumping, it should be fine. Also, that isn't the source of the leaks.
  2. Chris64

    NP203 removal and rebuild

    Just a tragic update, most everything is working fine although I now have some strange idling problem, but after sitting with transfer case full of oil, it has two small leaks. This was why I took the thing out. Sigh. Both places were places that used gaskets that came with a rebuild kit...
  3. Chris64

    NP203 removal and rebuild

    continued...And finally I borrowed my daughters sewing machine to make some little shift boots. I'm not totally happy with them. These are actually the seconds version. The first covered the whole lever so I just made these the same with half the height. Well, that didn't allow for enough...
  4. Chris64

    NP203 removal and rebuild

    Knob time! My dad bought this <$100 CNC engraver on Amazon and didn't understand how to use CAM software or program G-code so he gave it to me to figure out. So I finally gave it a try. First let me state that CAM software has not been keeping up with 3d print slicer software at all. Slicer...
  5. Chris64

    NP203 removal and rebuild

    I finally completed my shifter distraction and got everything bolted back and lubed. No leaks so far (knocking on wood). Here's the underside. I'm most impressed with the label on the NP203. That was under 1/2" of crud. Now that I look at it I don't think I plugged the vacuum hose in on the...
  6. Chris64

    NP203 removal and rebuild

    This project is still going (I don't have a lot of free time, I'm sure we can all relate). I built my first gen dual lever conversion. The cost was almost entirely scrap metal I had floating around. I started modeling the whole thing up in SketchUp and it was taking forever getting non-stop...
  7. Chris64

    NP203 removal and rebuild

    They're just wire hanger things like you see in the picture (#9) except smaller and shorter. One side has an open loop to hold the cable and the other has a 100 degree bend so it can hook on something if under tension. I don't see any wear marks on the cable or the frame though. Update: I...
  8. Chris64

    NP203 removal and rebuild

    Got it reinstalled! I still need to add fluid so I can't call it a success yet - but it's not leaking so far! The best tip I found when trying to figure out how to hold the gasket in place: Get some 3/8 16 (same as bolts) threaded rod and loosely put them in a few of the holes. This holds the...
  9. Chris64

    NP203 removal and rebuild

    So tomorrow will be attempt #2. Dumb question; I didn't realize until it was out that 2 of the 7 mounting bolts are a bit shorter than the others. I believe the bolts will fit in any of the locations. Approximate bolt layout: 1-2-3 4---5 6---7 I did find that some bolt holes allow you...
  10. Chris64

    NP203 removal and rebuild

    I thought I planned for everything :hahano: . I got the CG about as good as you can and it's already questionably tippy towards the front. I rolled it out to my truck following my line of pressure washed oil stain I left from the last trip. AND...it's now too high to fit under my truck. I had...
  11. Chris64

    NP203 removal and rebuild

    Oh it was plenty eye-balled :hahano: . I'm hoping this tool will work well enough that it won't be a huge effort to pull it back out and maybe clean it up more for more cleanup and/or paint some day. Also, I'm still just assuming I fixed the leaks. It may be coming right back out.
  12. Chris64

    NP203 removal and rebuild

    I finally built a little cradle to hold it level. I think I tried being too clever and made it sit at about 3-4 degrees leaning back to match the transmission. That just made the cuts all more complicated and the trans lift has an adjustment for this. Oh well. I need to see how much room I have...
  13. Chris64

    NP203 removal and rebuild

    update - taking the first part off which is the rear output, which also has the leaky speedo output. Then answer - no o-ring on the speedo :(. I could've resolved this without removing it. Oh well. I'll keep taking it apart and replace a couple gaskets and seals because I'm there but I may just...
  14. Chris64

    NP203 removal and rebuild

    All this research has me wondering if going to a dual shifter might be better. By the time I re-engineer this stock shifter to be serviceable (which is really less than perfect solution IMO) I could just fabricate a new dual shifter and never wonder if both levers are doing the right thing...
  15. Chris64

    NP203 removal and rebuild

    on this topic - and while I'm awaiting my UPS guy to show up - I removed the shifter assembly. Small back story: I had to shift this into low to get the truck into my backyard with the QuadraJet that could only run at an idle - so I could idle it up a hill into my yard. It wouldn't go back into...
  16. Chris64

    NP203 removal and rebuild

    It was tranny fluid I believe. If it's meant to be there - then I'm good. The more I look online the more unsure I am - but that part wasn't leaking so do I care? :hahano: :shrug:. I love the wooden cradle. 100% I'm doing that to get it back in there. I don't know what this weighs but it's way...
  17. Chris64

    NP203 removal and rebuild

    Looking around online, I need to replace the seal, which looks real simple on the 2wd's they show. Not the same for 4wd. Can this be repaired in place?
  18. Chris64

    NP203 removal and rebuild

    I needed to order a socket for the rear (1 5/16) so in the mean time, I'm just pre-cleaning the transfer case before I crack it open. Do these normally get painted or just bare metal? It looks like some of it was painted the same green as the truck but I'm not sure if that's original - probably...
  19. Chris64

    NP203 removal and rebuild

    OK - update -It was just residual oil from the transfer case. well, it's officially out and I still have all my digits. Putting it back in will be fun. As a bonus, I leveled it up in the stand to roll it all the way around my house. Unknowingly to me it started pouring out a 150' line of tranny...
  20. Chris64

    NP203 removal and rebuild

    dust cover aside - I have a short break before the weather turns dark on me. I'm cracking the last bolt and it started draining red fluid, which I assume is tranny fluid. I didn't expect that, I assumed these would be sealed from each other. I'm letting it drain now but wanted to check in with...
  21. Chris64

    NP203 removal and rebuild

    Mine looks more like it's a part similar to this, which with 51 years of dirt and grime looked like it was part of the trans.
  22. Chris64

    NP203 removal and rebuild

    Ahh - it looks liked stamped steel. I don't think it's a big deal although I will replace. At first I thought it was part of the trans block. I didn't get any pics of it - I'll post some up tomorrow.
  23. Chris64

    NP203 removal and rebuild

    I don't know what this means.
  24. Chris64

    NP203 removal and rebuild

    OK well it went about as expected - in that I think I'm doing something wrong. I took out the 7 bolts where I thought it started. Then I realized I wasn't removing the blocky part where the shift linkage connects to the transfer case. Oops. I looked online and saw someone else's 203 - these...
  25. Chris64

    NP203 removal and rebuild

    I don't think it has any braces on it. There's a big cross brace mounted to the back of the transmission and this appears to be just appears to be mounted to that. I'm working up the desire to get my hands dirty this morning. I should know more soon.

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