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203>205 Transfer case swap.

TJ1978

TJ1978

I have MANY questions
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I have some days off and figured this is the time to tackle this. If I can get motivated.

I have ORD competition motor mounts I want to install as well.
So, I suppose the course of action is.
First chalk vehicle, then.
1. Remove drive lines
2. Drain and remove 203
3. Support transmission
4. Motor mounts one side at a time
5. Remove exhaust to remove the transfer case drop.
6. Install 205, hopefully torque bar fits as well.
7. Measure for new or reworked drivelines
8. Drive with open headers to exhaust shop

With the motor mounts, I do have an engine hoist. Can this be used to do the motor mounts even with 4" lift and 35's?

Since I refurbished the 205, I can assume it's working as it should since it rotates as I turn it? And with the shifter installed it shifts as well.

Any advice is welcomed. That 203 is a beast and I think I'll open the doors and use the engine hoist if I can to remove it. I used a transmission jack last time and it wasn't too bad but a bit sketchy. Not sure how to support the 203 with hoist through the tranny tunnel
 
Shizzz I forgot I still need to order the coupler for th350/205 from ORD... damn.. I have two used ones but. I might as well put a new one in there since it will all be out...
 
That’s a little worn but it’ll do for a while till it don’t. Not worth the hassle for the low cost of a new aftermarket replacement.
I, in my younger days, installed the diy4x motor mounts with someone holding a prybar and me slipping them in. Easy. A hoist is good insurance that it won’t crush your hands.
 
I just went ahead and ordered a new drive sleeve...I guess I can still get started with all the other stuff...

Can engine mounts be a one man job with a lifted truck or is a little helped better?
 
I was thinking the coupler was a little warn on one side too, pictures can be deceiving.
I would do the engine mounts first or last.
I lifted mine by the exhaust manifold with a 2x4 and a floor jack. Headers don't lend themselves to this method. The engine hoist legs will be in the same area you'll want to be in, have to work around them.
Once you get the trans hump off you'll need to choose a spot to bolt a chain and lower the 203 down. Honestly going down with a 203 is much easier than in with a jack.
 
You think it's better to install the 205 with adaptor already attached to the cross member? I'm seeing pics and that 205 is at a funky angle to install even with a transmission jack.. if this is true then I'll have to wait for the drive sleeve to arrive before doing any of this.

I have no way of welding up a jig; I have scrap wood i could use to support it.
 
It helps cause tightening those bolts kinda sucks when you could just do four on the trans side.
It also helps stabilize it especially on a motorcycle trans jack type thing.

If you haven’t yet, install studs into the front of the 205 and the back of the trans. It really helps assembly and then you are sure you have full thread engagement.
 
Where does this star rubber oil seal thing go
Also
Do I rtv that gasket to the 205 and adaptor?

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That star washer goes on the end of the splines for a 32 spline output shaft. It seals the yoke splines. Does not fit a 30 spline front shaft right. Just use RTV or some ptfe thread sealant on the splines.

I do run a light skim coat on both sides of the gasket and that makes me feel better. Not sure if it’s honestly necessary.

ALSO that gasket better be real thick. Not like a paper gasket but like 1/16 thick.
 
obijuank5 said:
That star washer goes on the end of the splines for a 32 spline output shaft. It seals the yoke splines. Does not fit a 30 spline front shaft right. Just use RTV or some ptfe thread sealant on the splines.

I do run a light skim coat on both sides of the gasket and that makes me feel better. Not sure if it’s honestly necessary.

ALSO that gasket better be real thick. Not like a paper gasket but like 1/16 thick.
Click to expand...
I found the thicker gasket... rtv it and go.
 
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I made a jig to hold the np203 when I removed it. That tcase is heavy. Don't be any were around it were it could fall on you.

I did the np203-th350 to np205-th350 on a 78 k5. The original stock torque bar was not the correct length after the swap. I don't recall what vehicle works but the torque bar from another year/ tranny combo was a bolt in. So you will need to get another torque bar with a different length.
 
When I moved my niece's boy friend, might have been 20, picked up my old 203 and carried it 50' to the truck for loading, after I told him to wait for the hoist. :dunno: I don't think I ever tried to pick one up.
 
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