205 shift rails removal question

[72blazerguy]

What a day. Finally got time to assemble the 203/205 doubler. Was mating the 205 to the 203 and figured out that the shift rails had been installed with the longer rail on the wrong side. F*ck me, the doubler plate can't seat properly since the shift rail interferes. So much for not messing with the 205

So anyway, I researched some and it looks like the shift rails can come out if I punch the case plugs into the case and remove the roll pins. I have a few questions....is this the only way? what do I replace the plugs with? can I retrieve the plugs, how do i keep the shift fork in the proper position? are the roll pins re-usable?

Any input??

 

[bp71k5]

You can reuse all the parts, or at least I did. I'm guessing your going to have to break it down enough to be able to hold the shift fork in position when reinstalling the rails. I had something similar happen to me and I couldnt figure out a way to do it without disassembling almost all of it.

 

[76zimmer]

As above, I think so too, the fork needs to be held in position while you put the rail back through it. I don't know if you can achieve that without removing the rear output gear.

 

[72blazerguy]

Glad to hear that I should be able to reuse the parts. The case plugs feel pliable, but I was concerned that they would tear when i punch them through.

I was hoping that I could pull the rails out one at a time and hook the shift fork before removing the rail, but haven't punched the plugs through so I don't know if that will work.

Not very happy about having to tear the case apart. Guess I better start looking for gaskets. Will black RTV work in place of the paper gaskets?

 

[bp71k5]

The case plugs feel pliable, but I was concerned that they would tear when i punch them through.

Not very happy about having to tear the case apart. Guess I better start looking for gaskets. Will black RTV work in place of the paper gaskets?

Using a thin bolt or something that won't damage the plug. They're just tiny freeze plugs. I wouldn't trust rtv by itself but I know the gaskets are hard to find sometimes. I suck at rtv gasket making so if your good at it, go for it.

 

[72blazerguy]

Looks like I can get individual gaskets online (about $10+shipping). They have the plugs as well. The local parts stores haven't been much help lately. I don't have much faith in my gasket making ability and definitely would prefer not to pull this monster because of a leak. Getting the 205 out was enough work.

Still hoping that I won't have to get into the case

 

[4X4HIGH]

What a day. Finally got time to assemble the 203/205 doubler. Was mating the 205 to the 203 and figured out that the shift rails had been installed with the longer rail on the wrong side. F*ck me, the doubler plate can't seat properly since the shift rail interferes. So much for not messing with the 205

So anyway, I researched some and it looks like the shift rails can come out if I punch the case plugs into the case and remove the roll pins. I have a few questions....is this the only way? what do I replace the plugs with? can I retrieve the plugs, how do i keep the shift fork in the proper position? are the roll pins re-usable?

Any input??

Those rails are installed properly. The problem you're running into is there are two different shift rail lengths that GM used and you have the long one but you need the short one. The long rail has that other piece welded to it and the short one does not and is shorter. You CANNOT install the rails in the wrong side because of the detent grooves. You WILL have to remove the rear output in order to access the shift rail/fork. From the sounds of it the plugs in your t-case are the rubber plugs and not the smaller steel plugs. In any case the plugs can be reused but you will have to fish them out of the t-case after you have knocked them into it.

 

[72blazerguy]

Hadn't thought about the detent grooves. Glad to know that the guy that rebuilt that transfer case for me (several years ago) did it right.

Heh, now the hidden build costs start creeping in. Guess I will be ordering some gaskets and new shift rails. Looks like ORD carries new shift rails already setup for the triple stick. I'm only planning a twin stick shifter, but it won't hurt to have the shift rails for the triple stick.

On a more positive note, I will now know what the inside of both a 203 and a 205 look like.

 

[4X4HIGH]

Hadn't thought about the detent grooves. Glad to know that the guy that rebuilt that transfer case for me (several years ago) did it right.

Heh, now the hidden build costs start creeping in. Guess I will be ordering some gaskets and new shift rails. Looks like ORD carries new shift rails already setup for the triple stick. I'm only planning a twin stick shifter, but it won't hurt to have the shift rails for the triple stick.

On a more positive note, I will now know what the inside of both a 203 and a 205 look like.

Triple stick is just one for the range box and two for the 205 (twin stick). Anyhow that is your best bet since you need to buy a rail anyway.

 

[72blazerguy]

I am planning on 2 sticks total (twin stick). One for the 205 and one for the 203.

Anyway, wasn't too bad to take apart. Plugs were steel and I'm still missing one in the case, but gave up for tonight. Other than finding the other plug, I just need to get gaskets and shift rail and put it back together.

Can you cut these shift rails off? I was thinking of just chopping the long one off and putting it back together. Hole for the shift linkage is already there and it just needs the exterior end removed so it will clear the adapter plate.

 

[4X4HIGH]

You can cut the shift rail short BUT you will need the other style crossbar so the t-case will shift. Also if you only plan on a single shifter for the range box still and you buy a new shift rail from ORD you cannot buy a rail for twin stick as you CANNOT use a single shifter with it. I have the crossbar that you'll need if you cut your shiftrail shorter.

 

[72blazerguy]

Thanks for the good info and I will let you know on the crossbar.

I will talk to ORD tomorrow since they are probably my best bet for a shifter. Interesting point, the picture on the ORD website of the Long rails shows the hole at the end of the longer rail (wouldn't work to cut it off). If you look at this picture of my shift rails, the holes are at the same location on the rails. Almost looks like a hybrid.

http://www.offroaddesign.com/catalog/transfercaseshifters.htm

 

[4X4HIGH]

I goofed up, you have the short rail and you cannot run a single shifter on that doubler AFAIK since you have to cut the piece that is welded on off in order for that rail to clear the doubler adapter and without that piece you cannot use a single shifter. Looks like your doubler is an NWF doubler? You might want to call NWF and ask them about it.

 

[72blazerguy]

Unfortunately, it is a NWF doubler...as I just finished reading about another members issues with them. I was also missing hardware and no instructions soo, I would probably rather figure it out. Originally, I wanted to purchase a cable shifter from them, but things have changed and I won't be ordering that cable shifter.

Can't I just cut the rail and weld a piece back in that functions the same (clearance will be tight)? It seems that putting a twin stick on the 205 is going to be problematic since the doubler plate is interfering with a direct line to the longer shift rail. Also, from the pictures of the ORD doubler, they have the same issue and appear to use a much shorter rail where mine was the long one. In other pictures I have seen, the longer rail is on the passenger side.

 

[4X4HIGH]

I had an NWF style doubler and the same shift rail you have and I twin sticked the 205 and bought ORD's triple stick and it wasn't a problem. Let me dig up my pics to show you.

Crap, I just looked and don't have any pics of the triple shifter with the NWF style doubler (I swear I took pic).

At any rate, the triple stick shifter has a piece that slides over the shift rail and then moves the linkage out of the way of the 203 side adapter plate.

The piece circled in red attaches to the inside shift rail and then the stationary bracket supports it on the opposite end so the pull point is now half way inbetween.

 

[sweetk30]

triple stick ord shifter on ord doubler. and ord twin stick rails.

 

[ssyork]

There is always a way to fit shifters, just be creative.

 

[72blazerguy]

Thought I would update this in case anyone ever searches. This thread is probably misleading.

You don't have to remove the shift rails to get the doubler installed. I did and it ended up being a PIA. I ripped the 205 apart to get the shift rails out, but could have simply cut the tip of the rear shift rail off with a cut off wheel and moved forward with the doubler installation. This approach will not work if you want to be able to use Front Wheel only.

So here is a pic of the ORD triple stick shifter mostly installed. A big thumbs up to Stephen Watson and ORD. I had the triple stick shifter 1 day after ordering.