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Doubler shift question

Magikal

Magikal

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Quick question but i have searched and cannot find a straight forward answer. Recently installed 203/205 doubler and want to clarify shift positions at the transfer case. 203 has one shift lever at the case. Which direction is high and low? When the lever is rotated towards the front this would be high position? 205 has one detent rod for the front and one for the rear. Rod out of the case the furthest is high position for these?
 
Ok, i am not looking for shift pattern in the cab but physically at the tcase. Detent rod position coordinates to being in which gear?
 
Magikal said:
Ok, i am not looking for shift pattern in the cab but physically at the tcase. Detent rod position coordinates to being in which gear?
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It’s the reverse of the shift pattern

All the way forward on the shifter pushes the rod all the way back
 
So, detent rods all the way in equals low gear? Now what about the 203 section? Lever on the case rotated towards the front would equal low gear as well?
 
Magikal said:
So, detent rods all the way in equals low gear? Now what about the 203 section? Lever on the case rotated towards the front would equal low gear as well?
Click to expand...
Depending on how the lever is attached at the case.

Did you see my link above? Mounting the lever that way, lever forward is LOW. I.e rotating the shifter clockwise from the outside engages low
 
Bent77 said:
Depending on how the lever is attached at the case.

Did you see my link above? Mounting the lever that way, lever forward is LOW. I.e rotating the shifter clockwise from the outside engages low
Click to expand...

Ok. My lever is opposite cause its cable actuated and goes towards the rear, over the 205. .so that would mean that my lever pushed forward (clockwise) would be low gear. Correct?
 
Update: this info is correct. I ended up rotating the lever 180 degrees on my 203 cause the angle of deflection on my cable seemed to work better this way. Unfortunately on my triple stick i now have the 205 shifters forward for low gear while the 203 is back for low gear :poop:
 
If me I would flip the 205 spots . Get the front axle lever closer to driver as its used the most . Then your not reaching as far all the time .
 
i find my self shifting the front axle in/out the most . then rear shaft and 203 last .

my current ord setup is as the sticker so i am reaching over all the way . i have a 2nd doubler i bench tested the levers flip-flopped and shifts fine and lever is closer that i use all the time .

dont forget 203 low is last in first out . gives you the least chance of popping a shaft or input for the doubler .
 
sweetk30 said:
i find my self shifting the front axle in/out the most . then rear shaft and 203 last .

my current ord setup is as the sticker so i am reaching over all the way . i have a 2nd doubler i bench tested the levers flip-flopped and shifts fine and lever is closer that i use all the time .

dont forget 203 low is last in first out . gives you the least chance of popping a shaft or input for the doubler .
Click to expand...
Probably only exception for that is low load usage like backing up a trailer and such

But I’ve been told this several times about only using the 203 after the 205
 
i just did it from the start after reading it from ord and now its 2nd nature i always just do it .

but then i am not rock crawling ..... i use the doubler for easy work in low speed jobs and play time show off .
 
sweetk30 said:
i find my self shifting the front axle in/out the most . then rear shaft and 203 last .

my current ord setup is as the sticker so i am reaching over all the way . i have a 2nd doubler i bench tested the levers flip-flopped and shifts fine and lever is closer that i use all the time .

dont forget 203 low is last in first out . gives you the least chance of popping a shaft or input for the doubler .
Click to expand...

I read somewhere that 205 front was supposed to be last in/ first out.

I know you are not supposed to 203 low and 205 high together ...
 
Magikal said:
I know you are not supposed to 203 low and 205 high together ...
Click to expand...

I thought this was old news. In the early days of doublers, the intermediate shaft was made of 2 shafts welded together. Nowadays, all the companies are using new billet material for a 1 piece intermediate shaft. Much stronger this way
 
muddermilitia said:
I thought this was old news. In the early days of doublers, the intermediate shaft was made of 2 shafts welded together. Nowadays, all the companies are using new billet material for a 1 piece intermediate shaft. Much stronger this way
Click to expand...

Early stuff was typically a re-splined factory shaft and the better ones were re-heat treated. Our earliest versions were available with 10 spline and 27 spline intermediate shafts. You had to be particularly careful with those. Shortly after that we went to a 32 spline shaft only and they're pretty tough but it's still possible to break it by running with the 205 in high and 203 in low. This is actually the reason behind the Magnum, in that system we could make the shaft big enough that you can use it any way you want. With the 203 it's easy enough to run it right because there's really nothing to gain by doing it wrong since the gear ratios are so close together.

For a deeper dive into this: The reason the intermediate shaft becomes weak when the 203 is in low is that in that situation you have one 32 spline shaft going into the 205 and two 32 spline shafts coming out. If we say a 32 spline shaft has 4000ft-lb of torque capacity then we have 8000ft-lb of output capacity but only 4000 coming in. In that situation the outputs can be loaded to only half their strength and the input will snap. If the 205 is in low, you have the same two output shafts but also have a 2:1 gear reduction before them. So now the 4000ft-lb capacity coming in turns into 8000ft-lb going out and both outputs are at their breaking point before you snap the input. Chances are the outputs won't be loaded equally so you tend to snap an output before breaking the intermediate. And with that much torque on tap the real story is that you generally break axle parts before you have T-case problems.

Basically, we shift the 205 into low about the time we hit dirt and toggle the 203 in and out of low gear depending on the terrain.
 
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