Install 203

[TJ1978]

ok, I had it on my tranny jack and the shafts were linked but it just would not go all the way in to install the bolts through the adapter. First the wood was bumping into cross member, then on and on.

It seemed like the 203 was being slightly blocked by the cross member mounts. I used a screw driver to pry them open and push the 203 in but it just wouldnt go.

The best part was the 203 falling down, thankfully I was clear and was not hurt. I had it strapped down but needed some wiggle room, had to loosen it and welp. It just went. The strap did prevent it from slamming to the ground it was caught just came off the tranny jack.

Ok so here I am. I need some advice or ideas to get this POS installed.

The shit I have nobody to help. My poor wife was out here trying as I cursed and flailed around.

I have a tranny jack, jack stands, floor jack and straps.

 

[sweetk30]

make sure the shaft sticking out of the face of the range box is clocked correctly to mate up with the flat spot opening on the adapter face . seen this a few times .

 

[TJ1978]

I honestly do not see a “flat spot” unless you mean the yellow circle part? I was not close enough for that to matter. I could not even push it forward. It stopped when the bottom of 203 was close to the cross member.
I tried a wood and a hammer on the 203 and would not go forward.

I think it was the damn mounts but not sure. I dont know. The thing is so god damned heavy. And worrying about it falling trying to push and keep safe.... ugh



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[frankin5]

He is referring to the shaft on the lower front of transfer case fitting into the recess of the adapter. That shaft had a flat spot side as it is not round. Can you put a couple of cut of bolts in the TC to line it up and help keep into place to line up the shaft.

 

[TJ1978]

See edit... wasnt close enough for that to matter.
The weight makes this a really PITA to adjust

 

[frankin5]

Are the splines in the trans mating up to the TC. You might have to rotate the output shaft to line up.

 

[TJ1978]

It was on I just couldn’t get it to move more forward.
Bottom of the 203 seemed to be bumping up against something. I have a hunch it may be tranny mounts on the cross member. But hard to say, right about then it fell. And I gave up and sought some advice.

Its just me so it isnt easy..... hahahahahahah

 

[frankin5]

I would get three long bolts that will thread into the TC and cut the heads off to get them started into the trans. Then you could be able to adjust and wiggle the TC to get it to the proper alignment, without it falling off the jack so easily. If it is hitting the cross member you are not on the proper line, also if it had engaged the the output shaft, it should have aided you in getting it aligned. Sure glad i have a 241.

 

[TJ1978]

Im going to use what you say but also build a bigger a base to set the Tcase on. The wood I had on the tranny jack plate didnt hold the weight good enough.

 

[frankin5]

It is the pits working by yourself. i do it all the time. The older i get, the more I try to use every way I can think of to get the job done.

 

[warrpath4x4]

if you think its the mount, pull the cross-member off and see if the TC goes on easy that way.

 

[TJ1978]

I guess I can remove the cross member and support the tranny with my jack stands... hmmm

I just built a wider platform for the Tcase to set on and I may just take off the cross member

I knew this portion was going to be the most difficult just because of the weight of this POS.

But Ive had enough today. Long day at work 203 falling...
Time for a few brews..

 

[76zimmer]

Try to put a piece of plywood under the trans pan, get that crossmember out of there, then resume.

 

[HankScorpio]

Take a little time to get the t-case on the trans jack just right. A block of wood can help to get the tilt just right, its hard to get the offset case to sit on the flat plate. Attach it with a ratchet strap or something. Having the case on the jack well really helps when its time to fine tune the tilt and get the thing into place. Long bolts with heads cut off helps as well. I feel your frustration, last time I did a 203 it slipped like yours and I ended up pinned under the damn thing. I had the cross member off for sure. Good luck, you will get it in there the next time around.

 

[tenderfoot]

 

[diesel4me]

It is the pits working by yourself. i do it all the time. The older i get, the moreI try to use every way I can think of to get the job done.

I can attest to that fact--it does suck trying to get something heavy like this T-case in place alone...been there during engine swaps I did alone--but on the other hand,I've had "helpers" that worked against me too--tell them "pull it to the left",and they push in the opposite direction..or get in your way,or decide they know best how to do the job and want to supervise,and sulk if you refuse to let them be in charge..

I have been known to spend more time building or inventing something to make tough jobs impossible to do by yourself,than actually doing the job once I get the item made..or use things like a come-a-long or a winch as a second helper..work smarter,not harder,becomes your motto once your past 45-50 years old..

Once the hardest part of the install is over,I prefer working alone..

It is nice to have an extra hand ,and someone to call for help should something bad happen,but when I had someone helping me do an engine swap,about all I needed them to do was help drag the engine hoist away from the truck once the engine was hoisted up,push it back with the "new" engine,and help put the hood back on..

They can be distracting and annoying if they keep blabbing while your trying to think or do something difficult--and I've had a few "helpers" say they tightened those bolts--but they were finger tight after I did a double check later on--or they snapped one off and didn't say anything....its important the helper knows about vehicles and what they are doing,not every person is able to "help" when they aren't mechanically inclined..

The rest of the time,after I was not in need of 4 hands,they were more of a hinderance--not their fault,but when you have someone not as mechanically inclined or experienced "helping",sometimes it makes it harder,not easier..

Also having a helper,exposes them to potential injury,and that can be a major disaster if they end up wounded..you don't want a helper suing you for injuries they got helping,or see a friend end up hurt that was only trying to lend a hand..

 

[imiceman44]

See edit... wasnt close enough for that to matter.
The weight makes this a really PITA to adjust

Well you at least have a transmission Jack now.
I have done at least 5 with nothing just bench pressing and one time with a regular jack.
Now that I am older and I had a doubler on I finally got the transmission Jack and it was easy.
You do need to get the tilt right to clear the crossmember

 

[TJ1978]

I’m pretty sure I was off on the tilt but not by much.
Plus, long day and frustration werent working in my favor. After it fell. I walked away, after cleaning up tools.

Ill give it another go and after looking at the 2-3 pictures of the 203 online actually installed, my angle was off.

I wish I could just press this POS up and in but Im just not that strong. It is what it is.

I built a wider platform for the 203 to set on and tied down to the tranny plate, we’ll go from there.

Ill just take it slow.

 

[TJ1978]

Holy shiz was that f-ing difficult... After two more failed attempts today. Tcase is in.

I pray to the Gods all is well. I dont ever want to do this again. My wife helped and put up with constant swearing and banging my head against the frame rails.

Now I will go back one by one and loctite everything install the Tcase shifters etc etc...

Damn, what was GM thinking making such a hulking piece of a transfer case?



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[imiceman44]

Holy shiz was that f-ing difficult... After two more failed attempts today. Tcase is in.

I pray to the Gods all is well. I dont ever want to do this again. My wife helped and put up with constant swearing and banging my head against the frame rails.

Now I will go back one by one and loctite everything install the Tcase shifters etc etc...

Damn, what was GM thinking making such a hulking piece of a transfer case?

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Remember they didn't struggle with it, they build from the frame up, once the running gear is in they drop the tub on