NP203 thrust washer removal from input shaft

[73K5BlazerSS]

I hope someone has had this issue before me. I got the input shaft out ready to replace the bearings, but I can't get it to disassemble. It is really stuck on there. I removed 2 snap rings and I see a 3rd under the thrust washer. I believe there is a pin inside the indent on the thrust washer but that shouldn't stop me from removing the washer right? Any ideas... or do I need to press it off?

 

[73K5BlazerSS]

I found that the thrust washer pin was missing. This allowed the thrust washer to spin tearing up the surfaces which seized them together. I used a bearing splitter to get under the thrust washer and placed the bearing splitter on top of an open vise. Then I placed a wood block on top of the intermediate shaft and beat on it with a large hammer. Correctly installed the thrust washer should slide right off.

 

[imiceman44]

I found that the thrust washer pin was missing. This allowed the thrust washer to spin tearing up the surfaces which seized them together. I used a bearing splitter to get under the thrust washer and placed the bearing splitter on top of an open vise. Then I placed a wood block on top of the intermediate shaft and beat on it with a large hammer. Correctly installed the thrust washer should slide right off.

Is the shaft still usable or did this destroy it?

 

[73K5BlazerSS]

I'm not sure. I think I can file it down, although I don't know how exact everything has to be as far as tolerances go. The thrust washer looks pretty bad. I grinded the ID and OD with a Dremel so it can slide over the shaft again but the other 2 surfaces are galled.

 

[imiceman44]

I'm not sure. I think I can file it down, although I don't know how exact everything has to be as far as tolerances go. The thrust washer looks pretty bad. I grinded the ID and OD with a Dremel so it can slide over the shaft again but the other 2 surfaces are galled.

I think you might be better off finding a cheap used one and rebuild it.
Nothing special about this one.
They are a dime a dozen when you don't need one

 

[73K5BlazerSS]

Yea I see them for sale outside of my area of course. I don't exactly want to pay for shipping on an NP203. As soon as I'm done rebuilding this one another will pop up for sale around the corner.

 

[Chickntrk]

Starting to get hard to get parts for them too, Chains have to be custom made anymore. I've been collecting 208s for when my 203 finally goes or when I decide I want a front locker more than fulltime 4WD

 

[HankScorpio]

I have a bucket full of NP203 guts. I was going to probably weld them together for some metal art. If you need something send me a PM, I will check the bucket. One mans junk, another mans treasure.

 

[HankScorpio]

 

[73K5BlazerSS]

Any of you guys who have rebuilt a NP203 remember how the oil trough is mounted? This is my final piece of the puzzle. Mine is missing so I'm trying to fabricate one. It looks like a U shaped piece of sheetmetal that catches oil splash and directs it towards the rear bearings.

Does this piece just slide into a groove or something?

 

[73K5BlazerSS]

Here it is ( number 81 )