203 transfer case problems

[Dmax21]

I have 73 4x4 with a 203 transfer case with lock out hubs and I think it may have been converted but don't know for sure, anyways I was using 4x4 and while driving slowly the front wheels locked up and would not free up and I couldn't get the transfer case back to 2wd so I kept trying to backup and go forward and it freed up and made a pop sound and now the 4x4 will not work, I can lock it into 4lo and it will reduce the gears but no power to the front wheels. Now I haven't tore into anything yet but what do you guys think the problems could be or could have caused this? any tips would be great.

[El Dorado Jim]

the kits for the 203 transfer cases weren't very good, I had friends that had installed them to make them part time..had problems with them, the wouldnt last very long, had to have them rebuilt, i'm not sure why..in my 74, I replaced the 203 chain drive with a 205 gear drive trans case, that is what i would do if I were you....the 205's are bulletproof and will bolt right up to your transmission with the 205 adapter....find one in a wrecking yard...or watch craigslist.

[El Dorado Jim]

I have a t-350/205 t-case setup i would part with, but you are too far away, shipping would not be worth it...

[Dmax21]

What all is needed for a 205 swap?

[kwmech]

A 205 that was bolted to a t350, spline coupler and the adapter for the 205. Length of rear driveshaft will change as well as the front

[El Dorado Jim]

Originally Posted by kwmech

A 205 that was bolted to a t350, spline coupler and the adapter for the 205. Length of rear driveshaft will change as well as the front

and you will need the shifter arm also, totally different than the 203..

[sweetk30]

I have seen guys talk and post pics of the early not used as much now hard to find GOOD full shaft replacement to make them part time . . . otherwise most guys use them for the range box to make a doubler .

as said 205 will bolt direct to the th350 in place of the 203 .

adaptor for th350 to 205 fig8 pattern 205 only .

27 spline coupler sleave / or aftermarket 27 to 10 spline to use the more common 205 from behind a 4 speed stick . places like www.offroaddesign.com sell them .

shifter assembly for the 205 . . might wana think twin stick shifter . makes them shift like butter . and stock gets you 2wd/low and if modified 205 shift rail front wheel drive option. few places sell these setups like the link I posted above .

drive shaft length will be different also on both and possibly the front yoke style will be different on the 205 from the 203 . and if early 205 will be 10 spline and no swap over of the yoke from 203 .

crossmember will be the same . but might have to move it down the frame a few inches and possible drill new holes to bolt back in place .

[kwmech]

Originally Posted by El Dorado Jim

I have a t-350/205 t-case setup i would part with, but you are too far away, shipping would not be worth it...

How much?

[El Dorado Jim]

Originally Posted by kwmech

How much?

not sure, will talk to my son,will see him in a couple of days...

[El Dorado Jim]

If you are planning on keeping your truck for a long time I would definitely do the 205 swap, it is worth the time and money.......if you want to pm me and see if we can make something work....

[Dmax21]

I finally got to do some looking into my problem, so tonight I put the truck on jack stands and had someone watch the front shafts and it turned fine but no power to the wheels and it appears the hubs are locking in like they are suppose too, what do you guys think? Is it possibly something in the diff but the diff makes no noise while driving.

[sweetk30]

203 stock shifters get to be a real pita the older / dirty they get . some cant be cleaned and lubed there so bad .

might be a nasty shifter hanging up your shifting a bit .

[Getter-Done]

I sent you a PM yesterday with details. and I also agree with sweetk30
I think it is a shifter problem.

[jeffahart]

Originally Posted by Dmax21

I finally got to do some looking into my problem, so tonight I put the truck on jack stands and had someone watch the front shafts and it turned fine but no power to the wheels and it appears the hubs are locking in like they are suppose too, what do you guys think? Is it possibly something in the diff but the diff makes no noise while driving.

You saw the shaft spinning? did you see the outer shafts spin at the knuckle?

If the front shafts spin but the wheels do not, then the hubs are the issue.
So, if the wheels spin but the shafts do not, then you are not locked at the hubs.

If the wheels and shafts spin freely then your hubs are locked and the transfer is not engaged.

Think about the different modes you can be in.

1)transfer disengaged, hubs unlocked. (nothing spins)
2)transfer engaged, hubs unlocked.(everything spins under power but no power to wheels)
3)transfer disengaged, hubs locked. (everything spins from wheel, this is how most modern 4x4s run in 2wd).
4)transfer engaged, hubs locked. (4x4 power to wheels)

Your effect is like number 2 above... is that correct. If so, then look at the hubs, they're not locking. If the hubs were locking you would be at number 4 above.

[Dmax21]

Originally Posted by jeffahart

You saw the shaft spinning? did you see the outer shafts spin at the knuckle?

If the front shafts spin but the wheels do not, then the hubs are the issue.
So, if the wheels spin but the shafts do not, then you are not locked at the hubs.

If the wheels and shafts spin freely then your hubs are locked and the transfer is not engaged.

Think about the different modes you can be in.

1)transfer disengaged, hubs unlocked. (nothing spins)
2)transfer engaged, hubs unlocked.(everything spins under power but no power to wheels)
3)transfer disengaged, hubs locked. (everything spins from wheel, this is how most modern 4x4s run in 2wd).
4)transfer engaged, hubs locked. (4x4 power to wheels)

Your effect is like number 2 above... is that correct. If so, then look at the hubs, they're not locking. If the hubs were locking you would be at number 4 above.

I found the problem and it was in the diff.

[jeffahart]

Originally Posted by Dmax21

I found the problem and it was in the diff.

Opps.. missed that, sorry for blabbering on! Glad you got it fixed.

[Dmax21]

The reason I don't think it's shifter because when I shift the transfer into low it reduces the gear while driving which tells me the transfer is shifting.

[kwmech]

There are 2 sections to the transfer case. The forward section (bolted to the trans) is the gear reduction box. The rear section is the chain box, this spins the front driveshaft.

[El Dorado Jim]

do the 205 swap and have a real workhorse!

[Dmax21]

Well I found the problem the cross pin bolt had evidently backed and the cross pin slip down and broke.

[El Dorado Jim]

is that in the front end?

[Dmax21]

Yes it is