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203 part time possible issue

TJ1978

TJ1978

I have MANY questions
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78 k5 203 part time kit, warn hubs.
I put the truck in Park engaged the hubs, locked the 203 with the twin stick, selected Hi and Lo and all I got was chain noises, truck wouldn't go forward or backward.

Except one time I got it to go, I think. The chain noises stopped. Since the front drive moves in my videos whether in 2wd or locked 4wd, how do I know my locked hubs are actually engaged in 4wd moving forward or backwards

I wanted to see if it's working. I took video of the truck in 2wd and the front drive shaft spins in drive and reverse. Mind you this is going a few feet in my drive way back and forth.

I checked to make sure the that when in Park and hubs unlocked I CAN spin the front drive shaft by hand.

When I got the 203 to engage I took video and the front drive shaft spins in Drive and Reverse.

Then I tried again to engage 4wd again. Truck in neutral got it to lock but when selecting Hi or Lo all I got was chain spin noise and the truck would not move, same when in Park.

I read you're not supposed to use the 4wd on pavement but I need to see if this is working before going in the dirt or mud.

When I locked the hubs and put the 203 in Lock the front driveshaft will not move, as it's supposed to be.

Then I stopped, the chain noise was making me nervous something was going to break. Put it back in 2wd and went around the block, the truck drove fine.

Yes I still have the 205 but no $$$ to put it in yet.
 
Last edited:
Hey T.J. - ain’t seen/heard for a while!

A little confused on what is being asked but let’s start with the hub engagement - leave the trans in park and engine off and engage both front hubs. Now get under the truck and spin the front driveshaft by hand ( this will rotate the diff/axles and allow the hub gears to align up if they haven’t already ). The driveshaft should not spin freely due to the connection of the hubs - if it does spin freely then you need to look into why the hubs are not engaged.
Hope this helps.
 
tarussell said:
Hey T.J. - ain’t seen/heard for a while!

A little confused on what is being asked but let’s start with the hub engagement - leave the trans in park and engine off and engage both front hubs. Now get under the truck and spin the front driveshaft by hand ( this will rotate the diff/axles and allow the hub gears to align up if they haven’t already ). The driveshaft should not spin freely due to the connection of the hubs - if it does spin freely then you need to look into why the hubs are not engaged.
Hope this helps.
Click to expand...
Ok... basically how do I know when 4wd is working?

When I leave hubs unlocked and 203 UnLoc the front driveshaft spins freely by hand as it should.

When I locked the hubs and lock the 203 I cannot spin the front driveshaft. So that I assume the correct engagement?

When my truck is in 2wd or 4wd locked (when I got it to work I assume, one time) my front drive shaft rotated. Is front drive shaft rotation normal in 2wd?

Why is getting the 203 4wd to engage met with so much chain spin noise?
 
By rotate do ya mean that it moved to a certain point ( as in a ton of slop ) or did it spin as long as you kept rotating it ?

The noise could be caused by fluid resistance due to colder weather or the wrong fluid all together.
The 203 was originally spec’d with SAE30 motor oil for the viscosity they were looking for but a lot of folks end up putting in gear oil by mistake.
But most likely the excessive slip/noise is that it’s slap worn out or linkage slop.

It’s time to sell a kidney or inform the kids that y’all are gonna fast for a month or so and put that food money towards that 205 installment fund.
 
tarussell said:
By rotate do ya mean that it moved to a certain point ( as in a ton of slop ) or did it spin as long as you kept rotating it ?

The noise could be caused by fluid resistance due to colder weather or the wrong fluid all together.
The 203 was originally spec’d with SAE30 motor oil for the viscosity they were looking for but a lot of folks end up putting in gear oil by mistake.
But most likely the excessive slip/noise is that it’s slap worn out.

It’s time to sell a kidney or inform the kids that y’all are gonna fast for a month or so and put that food money towards that 205 installment fund.
Click to expand...
Spun as I kept rotating...
when locked and I tried there was little play.
It has the correct oil in it.

So... hahahah I'll try messing with it again, maybe. Or just leave it in 2wd and forget about it until I swap in the 205.

Is there a way to engage 4wd with the front axles on jackstands and the truck turned off? Just to see if when the hubs are locked the front drive is working?
 
In your first post "selected Hi and Lo and all I got was chain noises" you mean or ? not both at same time? I suspect your twin stick needs fine tuning.
I guess your t case would need a part time kit to use twin stick. Since this the replacement t case, it came with the part time kit installed ?
 
if you can't turn the drive shaft with the hubs locked that pretty much confirms they are locked. You could try and turn ea axle at hub to confirm they are both locked. Having an open diff in the front axle I would think that if one axle is not lock the drive shaft would still spin.
 
Wes Harden said:
In your first post "selected Hi and Lo and all I got was chain noises" you mean or ? not both at same time? I suspect your twin stick needs fine tuning.
I guess your t case would need a part time kit to use twin stick. Since this the replacement t case, it came with the part time kit installed ?
Click to expand...
Yes already past time kit... I'm not messing with detents and fine tuning, no way. I'd rather just leave it as in and not mess with the 4wd.

Can I check that the front drive shaft is engaging with the front axles on stands and shifting the 203 to loc and trying low and hi?


I've read that even if in UNlocked the front driveshaft will have "slave" spin but it's actually NOT moving the tires on the front axle
 
well I am not sure what you want to try here. Always sketchy tiring to run 1 half of a 4wd system in the air. If you can put both axles up and support them, yes you could try it. Slow speeds though, those 37's are a lot weight spinning around, and may not be balanced that well, possible to shake the truck right off the stands.
if you leave the engine off and do your checking by hand then yes, jack up the front and have at it.
 
Jack up front and will test by hand. I'm not putting this thing on 4 jackstands while running.. hahahahahaha
No waaaaaay dude...
 
Exciting news.... I see where my atf fluid is going....

Right into the 203. I mean I knew it was just being willfully ignorant..
i pulled the bottom bolt and the fluid is reddish mixed with the 30w oil...

I'm not pulling this entire driveline for that input seal..

What is a bandaid? Keep and eye on the tranny fluid level and when it drops drain the 203 a bit? I'm not wheeling this truck it's in 2wd 99% of the time. And I don't care about this 203 surviving, I have that 205

31823AE8-5F4B-402B-BE95-ED1A095639A7.jpeg
 
You can see how overloaded the 203 is. It poured out when the fill bolt was removed

144DD9A9-B769-405C-9137-09D1A32DAE11.jpeg
 
Check the vent, or hose, on top of the trans for blockage.
If plugged you will get atf in t case
 
Are you able to see/touch the chain through the drain or fill hole?
 
Blue85 said:
Are you able to see/touch the chain through the drain or fill hole?
Click to expand...
I'd have to go back out. I can check tomorrow I have errands to run.

What would being able to touch the chain or not reveal?
 
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