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question from the Hispanic Panic!!!!!!

Discussion in '1973-1991 K5 Blazer | Truck | Suburban' started by HispanicPanic, Sep 20, 2001.

  1. HispanicPanic

    HispanicPanic 1/2 ton status

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    ok here we go, when i give my tuck some throttle on a part that puts some stress on your rig (in 4 Lo) you hear a loud CLANK, CLANK coming from the T-case (NP203) im thinking its my chain skipping a tooth when hard torque is applied. my question is are those symptoms of the chain slipping

    <font color=purple>I put the Panic in Hispanic</font color=purple>[​IMG]
    <a target="_blank" href=http://4x4.alloffroad.com>4x4.alloffroad.com</a>
     
  2. chevrules

    chevrules 1/2 ton status

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    That is the chain,been there in years gone by.I hope all the NP203 people are using tranny fluid or motor oil in the case....never use gear oil!!

    chevrules...always has and always will
     
  3. HispanicPanic

    HispanicPanic 1/2 ton status

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    yea im using motor oil however 7 years ago some dumn ass added gear lube in it cuz it was low on fluid (about a qrt.) and i never drained it so i hope thats not what caused it.

    <font color=purple>I put the Panic in Hispanic</font color=purple>[​IMG]
    <a target="_blank" href=http://4x4.alloffroad.com>4x4.alloffroad.com</a>
     
  4. TorkDSR

    TorkDSR 1/2 ton status

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    it may sound like a t case but dont rule out u-joints. you have 9 of em, and they will gang up on you when you least expect it.

    Tork DSR
    I just got a winch, it takes the fun out of things.
     
  5. TorkDSR

    TorkDSR 1/2 ton status

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    it may sound like a t case but dont rule out u-joints. you have 7 of em, and they will gang up on you when you least expect it.

    Tork DSR
    I just got a winch, it takes the fun out of things.
     
  6. i_4x4

    i_4x4 1/2 ton status

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    7 years w/o a fluid change. Some maintainance Is due a little more often than that!!! I change my fluids in my diff's , t-case, and tranny at least twice a year. Spring and Fall. More often when i do alot of water crossings. Brake fluid, and antifreeze once a year.

    Later ED

    Get use to the view.
    Because, if your not the LEAD DOG the view never changes.
     
  7. Grim-Reaper

    Grim-Reaper 3/4 ton status Author

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    203 Chain replacement 101

    Chain. It's more of a Bang right? Looking at about $100 to repair. It's not a horrible job but doesn get you mad at times.
    Here is how to do it. You don't have to take the case out of the truck. I just did mine about 2 months ago in the truck.
    drain fluid.
    Take BOTHYoke bolt off BOTH the front output and the rear output.
    Remove the small section of the tail shaft. (have catch pan ready, you will have oil come out). Remove the shims, Speedo drive gear, oil pump (it;s a thin plastic gear like the speedo)
    Take all but one of the bolts out of the big section of the tail cone. Drink a beer. Have a BIG EMPTY catch pan under the tail shaft section. What I tried doing last go around is this. There are 11 roller bearings that the tail shaft ride on. If you leave the yoke and the tail shaft assmebly together the bearings WILL Fall out and go all over the place. If you push the tail shaft towards the case while you slide off the cone you can leave it hanging on the shaft while you remove the housing and then get your hand up there and catch those bearings. The Catch pan is a back up so if you drop them they won't go rolling down the drive.
    Remove the short tailshaft section and collect the 11 roller bearings.
    GET A RADIATOR CLAMP and put it on the remaning shaft to keep the top chain gear from sliding off the shaft. Learn from my experiance here. You REALLY don't want that top gear to slide off. There is 122 roller bearings that will fall out if a clamp is not kept on there to keep them in. I played pick up and once some come out, you have one heck of a time getting them back in.
    Now play with your sloppy chain and make it bang against the housing.
    Now take the s bolts out of the bearing suport cover for the front output.
    Take the bolts and yoke off the front out put. Take note of the way the front bearing retainer cover goes. There is a drain hole in the casting that must line up so that the oil will flow through the bearings.
    Once that front cover is off you can pull the bearing out of the front and the lower gear will have enough slop that you can fish it out.
    Drive the roll pin out of the shift fork (this is fun in the truck) and remove the shift fork.
    Feel around on the top of the case where the shift fork rod is and you will find a recessed bolt that retains the detent spring and ball. Remove it and fish the ball out with a magnet.
    Ok take all the bolts out that hold the two halves of the case together and pop the gasket loose.
    You need three hands or 2 hands and a dextarious foot at this point. The chain will have to be lifted off the gear so you can slide the case of the back. The shift rod will also fall loose and leave you with a thin rod with a hook hand out of the back of the reduction box pay attention to the way it's turned.
    Clean everything back up. Drop the chain in the housing. Get those 2 hands and foot hold you toung just right. Hold the chain off the top gear, line up the shift rod with it's mate, tiwst the housing into posision, Get the new seal lined up, get a bolt in it, Cuss all at the same time till you suceed geting it all lined up and on. It's fun. Friend helping is nice.
    Once that housing is in place the rest is the reverse. When you get to the point of needing to install the 11 roller bearing put some axle grease in the hole and line up the bearings. this will hold it will you can get it on the shaft. Don't forget to remove the radiator clamp [​IMG].
    Once you get the big part of the tail housing on you need to put the shims in. If you look the small part of the tail shaft has a O-ring seal. Make sure it's in good shape. Once the small tail peice is on you want to check for end play. You need just a hair of in and out play. Just a hair. if you pull on the shaft (put the nut on it) you should just barly feel it move out and in. Less is better but it need some. the Spec is like 2thousands. This sets tha lash for the diff/part time kit. To loose and it will create excessive drive line slop.
    Fill it up with oil. Before you put the shafts in put it in LOC Fire it up, put it in drive and let it spin. Get under and listen for any weird noises and grinding. Running it like this for a couple minutes will also sling oil back into the resivior for the tail shaft bearing.
    IMPORTANT! put the truks transmission in N and shut it off. DO NOT TRY TO SHIFT TO PARK till the engine is off.
    Check the fluid level again. you will need to add some once the case s run.
    Put in your drive shafts and your set.
    Takes a good long Saturday (and part of a sunday if your Anal like me and had to clean it spic and span and paint it Chevy Orange). Also when it's appart there is a magnet on the lower section of the housing. Do your best to get the shavings off it. If you got a compressor a blow gun seems to work best.
    Now here is the deal. The chains can do 2 things. Streach and wear. You may lay the old chain next to the new and not find any real difference in Lenght. What has happend is the chain has worn where it rides on the gear so it gets all the slop in it. Once you have it on the gears you will notice how much tighter it is on the gears than the old one.
    Have fun!

    It's not my damn planet monkey boy!
    <a target="_blank" href=http://communities.msn.com/OffroadK5s>communities.msn.com/OffroadK5s</a>
    75 Jimmy, Dollar
    79 Chevy Blazer, Her's
    70 Chevy Burb
    Grim-Reaper
     
  8. Kyle89K5

    Kyle89K5 1/2 ton status

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    Re: 203 Chain replacement 101

    quit typing this stuff out in a post and put it in a dang writeup [​IMG]

    I think we could find you a junk 203 for you to use as a reference for pics.

    Kyle
    89K5
     
  9. CK5

    CK5 In my underwear Administrator Premium Member GMOTM Winner Author

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    Re: 203 Chain replacement 101

    I agree, it looks like we have the write up, we just need the panic to take pics when he does it. [​IMG]

    Steve

    Bandwidth FREE ZONE

    Mall-Running poseur 4x4 with curb-feelers
     
  10. beater74

    beater74 1/2 ton status

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    Re: 203 Chain replacement 101

    i vote that grimmy should have his own forum and we can call it grimmy work bench. with vast knowlege he has on everthing we could all learn somthing. and with ALL the free time he has we should be able to keep him busy HEHE. once again thanks grimmy that info not only help Hpanic but me as well.
     
  11. HispanicPanic

    HispanicPanic 1/2 ton status

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    Re: 203 Chain replacement 101

    Holly crap Grim you are bad ass i will talk to Scooby Dann and see if he can help me out with the project and take some pics to post when we are doing it and when we are done. thanx a bunch [​IMG]

    <font color=purple>I put the Panic in Hispanic</font color=purple>[​IMG]
    <a target="_blank" href=http://4x4.alloffroad.com>4x4.alloffroad.com</a>
     
  12. SCOOBYDANNN

    SCOOBYDANNN 1/2 ton status

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    Re: 203 Chain replacement 101

    looks like were gonna have some FUN!!

    You know who I am
     

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