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78 k5, weird 4x4 issue

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JACKBURTON55

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OK let me preface this with I dont have a lot of offroad experience, so dont beat on me too hard but tell me how it is.

THE TRUCK:
78 K5, 350/350 with np203 with part time conversion kit.
INFO:
The transfer case pops out of gear if you dont hold it in, however, if hold it in, it will stay in 4hi lock, if i put the case in 2h, it will drive for a second, then slip and i hear this spinning noise and i can just rev the engine, no drive. The same goes for 2low. I currently have a redneck rigged job of chains holding the shifter in place.

Hubs were bad and missing parts, got some new warn premiums. just installed them.


THE ISSUE!:
I go to lock the hubs, and begin to drive off, truck is definitely in 4wd, and is pulling slightly to the right(is this normal? on concrete) I speed up ever so slightly and begin to feel something binding up, and then pops, as some kind of pressure is released. I stop, look under, everything is fine, and truck is still running. Put hubs in free, drive backward and what not, make sure they are unlocked, and park it and get on here.


SO what does this sound like? All the issues with my tcase and popping out of gear would have me believe it is the culprit with the 4wd not working. Thinking about it now, I dont think that 4wd on concrete is good, but this was a full time 4wd truck at one time right?

HELP, i want to fix it and go wheeling!
 
Better yet throw 1/2 the 203 out get the combo adapter AND 205 put the doubler back in good to go..
 
So you were driving on pavement in 4hi? It probably was binding because 1 you were turning some, 2 the rear tires are worn down more than the front, making them a different size, or 3 the front and rear ratios do not match.
 
Last edited:
The 203 is a decent T-case, and the popping into nuetral is very common. It's very common even if you're just using the range box part with a doubler. The detent mechanism for the different ranges isn't the most aggressive. You can remove the hex head bolt from underneath and add a washer or two under the detent spring and that will firm it up enough that it will stay in the range you put it in.

i had to do this with a 100% rebuilt range box. It did the same thing...you accelerate some and everything is cool, but as soon as you let off the gas it'd pop into nuetral all by itself.

Rene
 
The 203 case gets a bad wrap for the craptastic shifter that is stuck on top of it. I agree I would rather have the fixed yoke of my 203 rather than the slip yoke of a 208 :D.

In any case tRustyK5 has a good suggestion on stiffening up the detent.

The main issue seen with these 203s is the shifter just being gummed up with old grease and dirt and not being adjusted properly.

First thing I would recommend is to remove the shifter and clean it up with your favorite degreaser then make sure it is well lubed and moves freely off the truck. I use a spray white lithium grease with a straw to get the lube all up in the shifter. reinstall and adjust the shifter according to the instructions in this diagram.

The other option is to just ditch the complex single shifter and either install a twinstick from ORD or make your own.

As far as the binding on pavement, depending on the severity, this is normal. you have converted from full time to part time which eliminates the center differential in the 203. I would recommend trying your 4wd on loose dirt. You can usually find a stretch of area next to a road that has loose dirt that will allow the slight amount of wheel slip that a part time 4wd requires to reduce binding in the drive train.

If the binding is really bad as others have suggested, verify gear ratios front and rear, verify tire sizes and wear that would change tire size.

On edit: I just noticed that you are not a member so you wont be able to see the attachment. here is a link to it on another forum, not sure how long the link will last but worth a shot if you can see it there.

http://www.plowsite.com/showthread.php?t=2537

203shiftdiagram.jpg
 
Hey guys thanks for the replies, sorry im late on mine(not that you guys probably care) but I do thank you for attempting to resolve or shoot questions or solutions at my problem. That makes sense about the binding now, my truck has different wheels on the front and back, need new tires lol but im working on the other mechanical s first.


I think I will get the ORD shifters, they arnt that expensive really. IF that will fix it, then ill be set, i dont mind full time 4wheel drive. Plus all the drive shaft lengthening and shortening sounds expensive for an np205
 
rufusbooth said:
The 203 case gets a bad wrap for the craptastic shifter that is stuck on top of it. I agree I would rather have the fixed yoke of my 203 rather than the slip yoke of a 208 :D.

In any case tRustyK5 has a good suggestion on stiffening up the detent.

The main issue seen with these 203s is the shifter just being gummed up with old grease and dirt and not being adjusted properly.

First thing I would recommend is to remove the shifter and clean it up with your favorite degreaser then make sure it is well lubed and moves freely off the truck. I use a spray white lithium grease with a straw to get the lube all up in the shifter. reinstall and adjust the shifter according to the instructions in this diagram.

The other option is to just ditch the complex single shifter and either install a twinstick from ORD or make your own.

As far as the binding on pavement, depending on the severity, this is normal. you have converted from full time to part time which eliminates the center differential in the 203. I would recommend trying your 4wd on loose dirt. You can usually find a stretch of area next to a road that has loose dirt that will allow the slight amount of wheel slip that a part time 4wd requires to reduce binding in the drive train.

If the binding is really bad as others have suggested, verify gear ratios front and rear, verify tire sizes and wear that would change tire size.

On edit: I just noticed that you are not a member so you wont be able to see the attachment. here is a link to it on another forum, not sure how long the link will last but worth a shot if you can see it there.

http://www.plowsite.com/showthread.php?t=2537
Click to expand...

special thanks to you sir this was very useful information
 
No problem, one thing that you might want to try is disconnect the shifter leaving just arm g and arm f (referring to the adjustment diagram). Set the arms in one of your positions you are having problems. Then, try to drive it. The transfer case should stay in gear without the shifters connected and will identify if the shifter or the case is the problem before you shell out the $ for the ORD stuff (unless you really want them :-).

If the transfer case still pops out of gear then try the washer trick under the detent that tRustyk5 mentioned.

Rufus
 
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