203 transfer case manual

Clean the case so that no dirt can get inside when you start to tear it down. Transfer case np203 rebuild kits drawing and parts list. Chevy 350 turbo 203 transfer case adapter np203 np 203 doubler 70. The np261 transfer case was manufactured by new venture gear. This manual has approximately 100 pages of everything you need to know about rebuilding an np203 or np205 tcase. The owners manual recommendation is to use sae 30 nondetergent. If you need help with flywheels or clutches, transtar industries is here for you. May 22, 2009 any transfer case that can be twin stickd can disengage the front axle while running the rear in low range.

One response to 203 transfer case in early bronco daniel hart says. The 19701980 4x4 350 turbos came with short rear tailshafts, and were made to work with the np205, and 73up np203, and while the 205 used an adaptor with coupler inside it to spline into the transt case. Details of the np203 used by each manufacturer are as follows. The novak guide to the new process model 200 transfer case. Chevygm did not offer manual hubs with the 203 case, as, it was full time. Installing the conversion allows the case to act like a part time case. Parts breakdown, service manuals and owners guides free to view and download. If you need any assistance identifying the model of your transfer case or the needed part, we can help. Im looking for a suggestion for the oil to use in a np203 transfer case. For off road use, the 203 had a lock position in which the differential was locked making the front and rear outputs spin at the same speed like a normal part time transfer case. It is also found in ih and ford vehicles as well as a limited run of gm trucks in the earlymid 1970s. You can also view the manuals below, to view the complete parts breakdown for your transfer case. W hen most people think of the new process 203 transfer case, two things come to mind. Np203 np205 atsg transfer case rebuild manual 203 205.

Note the front case half is aluminum on this version, while the rear is magnesium, like all other bw56s. Ive been trying to find the back half of a 203 for awhile, if you could contact me that would be great. Np203 new process transfer case diagrams and information. E252 housing, rear case bw70 1 8900 ae tc70223r e254 housing, rear extension bw70 1 8900 ae tc70225r transfer case chains b280 chain, drive 72 links 1. The np203 transfer case was used by dodge from 19741979, ford from 1974 to 1979 and chevrolet and gmc from 1973 to 1979.

Markings on the dana 20 can vary, but most start with a c181524. The np205 was the sole transfer case choice for all 1980 gm 4. Ever since i have owned it the transfer case has shifter rather hard and finally i decided to try and adjust the linkage. There are a lot of needle bearings that fall when disassembling this case. The overall length of the np203 case is 2223 from the face of the case to the rear output yokes.

Manuals may be obtained by calling the to meritors customer service center at 8005355560. Follow along and look at the photos provided then you will be ready. It will also mate to manual transmissions such as the np435 that have a 31spline male output. Chevy transfer case 203 community chevy automotive sales. I was rebuilding the whole case when i purchased this kit, installation is not that hard, but its not that simple either. I followed the instructions per the gm shop manual and got a lot of slop out of the shifter. Chevy gmc transfer case rebuild what to repair pt 2 youtube. The chevy np203 bolt pattern is a unique, 7bolt asymmetrical pattern, as seen in figure 4. Drain all oil from np203 into a container and discardrecycle where safe. Atsg cdrom manual for np203np205 transfer case 1969up. In 1971, new process introduced a model np203 chaindriven, and np205 geardriven transfer case. Is there something that would be better from the perspective of protecting gears than a motor oil.

Installation manual for your np203np205 adapter kit. This is done by removing the 6 bolts that hold the tail housing to the chain case. If you know the part number of the transfer case, for example, if the model number is t223h36, you simply match the item number in the. This manual has approximately 100 pages of everything you need to know about rebuilding an np203 or np205 t case. Ford and dodge np205s use 32 spline fixed outputs front and rear, always. Jordan,mn members transfer case 203 manual preferred customers preferred. There is a short bearing retaineroutput housing at the tail of the case, and aluminum bearing retainersseal retainers at the front and rear outputs but the working parts are all in a single iron housing. Ford available behind c6 automatic transmissions, the ford np203 has a 31spline input and ford 6bolt circular bolt pattern.

The np205 was manufactured with manual shift, it is a replacement unit for the earlier units, it is a part time case. As a general rule, all of the transfer cases that couple to a th350 automatic are normally a 27 spline input. It is an all wheel drive transfer case for full size pickup trucks. Dodge used the np203 behind both tf727 autos and np435 manuals from 75 to 79. The novak guide to the dana spicer model 20 transfer case. Mar 09, 2009 the owners manual recommendation is to use sae 30 nondetergent motor oil. They were originally a full time 4wd case, meaning all 4 tires receive power at all times. You can contact us by calling 8777764600 or 4078721901. The np261 transfer case is used for more heavy duty applications, being reserved for mostly truck and van use. Installation manual for your np203np205 adapter kit step 1. This transfer case is a good gear box with a low ratio of 2. E195 housing, front case bw70 1 8900 ae tc70220r e245 shaft, shift bw70 welectric shift 1 8900 na tc56209 e248 cam, electric shift bw70 1 8900 56099008 tc56208 e252 housing, rear case bw70 1 8900 ae tc70223r e254 housing, rear extension bw70 1 8900 ae tc70225r transfer case chains. Fullsize ford truck transfer cases blue oval trucks. Manual front hub, conversion, chevy, ford, gmc, with np203 transfer case, kit.

The weakest part of this transfer case is that the shifter fork wears easily, causing shifting problems. This kit converts your fulltim 4x4 np203 transfer case into part time. The transfer case is made up of 4 sections bolted together, a range box, the chain case which houses the chain drive to the front driveshaft output, the differential housing, and the output housing. The dana 20 is a cast iron transfer case, having a passengerside front output and a centered rear output. Transfer case manuals, operator guides, parts and service manuals. The fulltime fourwheeldrive np203 transfer case is one of the most standard items found in 70s fullsize 4x4s. Here is a documented tear down and rebuild of this unit. The nv4500 came in dodge and gm output configurations and the one thats used to mate to the np203 is the gm 4wd nv4500. Our comprehensive stock of parts for air braking systems, hydraulic braking systems, and air suspension systems includes everything from air compressors, valves, reservoirs and brake actuators to airline couplings, pipe fittings, nylon. S ticks out 31116out from the front of the case once installed. Available as part time or fill time, torqueondemand. In addition to bearings, gaskets, and seal kits, transtar offers a complete line of transmission and transfer case hard parts. It was supplied in many gm, ford, international and dodge fullsize trucks.

The np203 is a chain driven full time transfer case. This transfer case uses a larger front bearing than the 10 and 27 spline transfer cases. The np205 gear driven transfer case is considered by many to be the king of bulletproof. Many of the fullsize chevrolet vehicles have used the 203 units. Hang out in the garage with me as i clean up and assemble an np263 hdgm transfer case to correct common failures, make fixes, and show how to install new sea. Mile marker transfer case conversion kits free shipping on. Has a combination of 2 high, 4 high, neutral and 4 low.

When i bought the truck it already had a conversion kit in the transfer case. Compared to the np203 and np205, the lightweight cast aluminum housing of this transfer case is easier to handle. Some confuse them for a large case dana 18 because of this. The front driveshaft will not receive power when in 2wd the transfer case is gear driven, 1. The wellknown np205 transfer case, that was available in many civilian trucks beginning in 1969, is an outgrowth of the np200. The new process 203 was used in gm, ford, and dodge through the 70s behind auto and manual transmissions. Give us a call 8002161632 and let us help save you some money, ask about used parts. The purpose of the conversion is to save driveline wear. Chevy transfer case 203 community chevy automotive sales inc. This uses a 32 spline output shaft and an adapter housing thats approximately 7 long. I was reading through your install nice work, and noticed you werent going to reuse the chain and diff from the 203. Im looking at a 78 chevy suburban and it has the np203 transfer case with manual locking hubs. Im new to 4x4 and wanna know how to use this transfer case.

The np208 transfer case is similar to the np203 and np205 cases, sharing a number of applications between them, though on the 208 the casing is made out of aluminum rather than iron usage. This is one heavy and awkward unit so use caution when lowering. Introduction this parts book is designed so that you can look up part numbers in two different ways. The most notable differences between the bronco dana 20s are the early version 6672 known as the tshift with 2. Dana 20 transfer case wild horses early ford bronco parts.

Nos 19731979 chevygmc truck type 203 transfer case oil pump seal gm335181 dp 15. Remove np203 from transmission if necessary step 2. Order 203 part shop by brand shop by aircraft deal of the. M440 melroe borg warner 56 transfer case manuals national survival service manual 26 mb djvu v 4 33. Found in 198591 vehicles, this transfer case has a long stick out of approximately 3. We support almost all makes and models old or new, foreign and domestic, lightduty trucks, passenger cars and performance applications. The np208 was manufactured with manual shift, it is a replacement unit for the earlier units, it is a part time case, the front driveshaft will not receive power when in 2wd. The rugged and reliable, parttime, np205 with a fixed rear output shaft was also used from 19731979, primarily on vehicles with the sm465 4 speed manual transmission. After the bolts have been removed, smack the housing with a deadblow hammer to loosen the seal.

Lower the tranfer case and place it on the floor or work bench. Np205 transfer case midwest transmission center, inc. Figure 4 front input of chevy np203 showing asymmetrical 7bolt pattern and 10spline input indicating sm465 version. If you require an np203 transfer case rebuild kit for gm vehicles, including chevrolet np203 transfer case. We stock a complete line of manual transmission and transfer case parts. Atsg transfer case rebuild overhaul manual np203 np205 203. The front 2 sections are cast iron, the back 2 sections are typically aluminum. Manual items not specified 119 items 119 see all.

Big, heavy, and relatively strong despite its chaindrive, this box can be converted. Transfer case manuals, operator guides, parts and service. This can be done without a press, and with basic tools. We offer only quality rebuild kits that include all the component replacement parts you need to service your manual transmission and transfer case. Np203 transfer case illustration exploded view is provided to assist you in identifying parts and assembly sequence details. Chevynuts 6791 gm transfer case drivetrainaxle guide. Np 203 transfer case shifting problems snowplow forums. So, whether you need a case, a gear, a chain, or synchro rings, we have. Please visit our partner site makco transmission parts for tc repair manual np 203 transfer case repair manual products found in this category. Are you having problems with your np208 transfer case and need a rebuild kit or replacement parts. Mile marker transfer case conversion kits free shipping.

This one is a book on cdrom for a new process 203 or 205 transfer case used in many 4x4 ford, gm, and dodge trucks with cast iron transfer case please email for specific applications from 1969up. B6 hub, mode bw70 w manual shift 1 8900 ae tc70197r c150 collar, mode bw70 welectric shift 1 8900 ae tc70203r. It was introduced in 1969 and used until about 1993. This manual has approximately 100 pages of everything you need to. Very beginner question, how do i use the np203 transfer case. Left side drop output and has a low gear ratio of 2.

Both of these transfer cases used various input splines. Oct 24, 2017 the np205 transfer case is a heavyduty, geardriven unit manufactured by new process gear in syracuse, new york. The new process 200 transfer case was jeeps first use of a nondana spicer transfer case. The np203 transfer case np203 manual transmission is a fulltime, chaindriven unit used selectively by ford, gm and dodge on fullsized pickup trucks from 1973 to 1979. This transfer case was installed in dodge 19801987 ford 19801986 gmc 19811988 jeep sj 19801990. There is a small idler shaft cover on the back of the 205 with 3 small bolts holding it on. The transfer case is made up of 4 sections bolted together, a range box the gear reduction we use for the doubler kit, the chain case which houses the chain drive to the front driveshaft output, the differential housing, and the output housing. The new process np208 transfer case is a strong, reliable unit that features 2. Transfer cases for gmc and chevy vehicles got transmissions. Secure the transfer case to a transmission jack or other suitable jack, and remove the mounting bolts note. How to rebuild a new process np transfer case youtube. Np203 transfer case the new process 203 was used in gm, ford, and dodge through the 70s behind auto and manual transmissions. If you require an np203 transfer case rebuild kit for gm vehicles, including chevrolet np203 transfer case parts, we may have exactly what you need right here.