NP203 w/Mile Marker Kit Issue

[GoAWOL]

When re-assembling my NP203 transfer case after installing the Mile Marker kit, I managed to crack my tail housing...the one in the pic. I'll run to the pick and pull and get another one but what worries me is why the original one didn't seat all the way in the first place. The larger tail piece fits snug...this smaller one that sits on top of the larger one had about 1/8" space and wouldn't seat any farther...hence why it cracked.

Any ideas?

 

[herkdriver007]

Without going into the garage to look, could it be the housing binding against the output shaft?
If you can't locate a new tail housing in the 'yard, let me know...I've got one you can have for the price of shipping, or any other small parts as well.

Good luck!

 

[GoAWOL]

Without going into the garage to look, could it be the housing binding against the output shaft?
If you can't locate a new tail housing in the 'yard, let me know...I've got one you can have for the price of shipping, or any other small parts as well.

Good luck!

Appreciate it, might take you up on that offer. Don't think it's binding on the shaft. I think it's either the speedo gear is hitting the speedo sensor gear or I put it all together wrong.

 

[herkdriver007]

As I was taking the tail apart, looks like maybe you're binding w/the speedo gear? Well coming apart I could tell the resistance...

 

[GoAWOL]

As I was taking the tail apart, looks like maybe you're binding w/the speedo gear? Well coming apart I could tell the resistance...

It just may be that although I'm afraid it will probably be something with how I put it all back together. I appreciate you sending the part..when I determine exactly what I biffed up I'll be sure to post up the findings and hopefully the fix.

 

[goathearder]

If I remember correctly there are possibly some shims at the end of the tail housing and I think mile marker may have even made you use a thicker gasket. Maybe check and see if one of the shims slipped loose and is making it bind?

 

[GoAWOL]

If I remember correctly there are possibly some shims at the end of the tail housing and I think mile marker may have even made you use a thicker gasket. Maybe check and see if one of the shims slipped loose and is making it bind?

You're correct, there are shims there. I pulled them off and tried it without them...no dice. Herkdriver007 has been gracious enough to ship me a replacement for cost of shipping (awesome, thanks again Doug) and when I figure it all out I'll be sure to post up the results.

 

[GoAWOL]

Whoo hoo...part arrived today. Thanks again Herkdriver007 for being gracious enough to ship the part for cost. Not just a CK5 member but a great guy to boot

 

[herkdriver007]

Glad it made it safely! Now hurry up and let's see what's causing the problem!

 

[GoAWOL]

Glad it made it safely! Now hurry up and let's see what's causing the problem!

Went and did an initial fit last night and it snugged up nicely. That leads me to believe that I assembled the bearing or speedo gear incorrectly in the other one. If you look at the first pic I posted, the seal isn't flush with lip of the assembly...yours was.

More to follow but early reports indicate success!

 

[herkdriver007]

Excellent! Glad to hear!!!

 

[GoAWOL]

Finished Product

Thanks to CK5 member HerkDriver007 I was able to complete my Transfer conversion. Here is a pic of the before and now the finished product...

 

[herkdriver007]

Looks great! You sure that's the same tail housing? Um the one I sent was hella dirty!

 

[GoAWOL]

Looks great! You sure that's the same tail housing? Um the one I sent was hella dirty!

I agree...it was hella dirty. But, just add it to the list of 40+ year old parts I have been and still am trying to clean.

I think it turned out pretty damn nice for a piece of gear that won't be seen unless you crawl under the truck

Thanks again.