Ord doubler help

[MuddinK5]

sup every one. ok i just caught a pretty good deal on a doubler so i jumped on it lol. i have a couple questions about it tho (im a total noob when it comes to this doubler thing) ive done searches on all of this and even searched for instruction and i couldnt find nothing so any help would be appreciated.

1. the 205 was partially taken apart because po said it was making a weird noise, so he came to the conclusion that it needed shims on the idler gears. so how much side to side movement should there be on them gears? right now they move back and forth a good bit.

2. i was test fitting everything together and i noticed the tcase adapter for the 203 does not fit flush because there is a circular knob like thing that is flat on the bottom that sticks out is hitting the adapter. there is an indention in the tcase adapter that it should fit into but its not lining up right.

3. its a triple stick setup and the shifter linkages were already bolted to the shifters so i just attached them to the 203 and 205, well i noticed that 1 of the screws on the 205 shifter levers is contacting the 203 shifter lever and not allowing the 203 to shift properly. it looks like th screw is too long so im tempted to just trim it but i just want to make sure 1st its not like that for a reason.

4. and my final question the 203 has tWo levers to hook a shifter linkage to i did a search to figure out which 1 to use and i noticed that ord makes a kit to twin stick a 203 (i was totally unaware of a twin sticked 203 lol) well it looks like my 203 has the exact same twin stick brackets on it so which 1 do i use?

ive attached pics of what im having trouble with. thanks for any help

this little knob thing is suppose to fit into a notch the same shape in the tcase adapter but its not lined up.

heres the tcase adapter, theres the notch it should fit into. i tried to just simply rotate the knob thing wit an adjustable wrench but it wont budge.

with the adapter on this is the gap, i know this cant be right.

another pic of the gap

here is the bolt thats interfering with the shiftage of the 203 range box. the shifter to the far right is for the 203 range box the bolt that goes threw the linkage is too long and stops it from functioning properly. should it be like that or is it safe just to go ahead and trim it?

last but not least here is the 203 range box as you can see there are 2 brackets which 1 is the correct 1 to use?

this is what it looks like connected to the 1 i think is the right 1.

everthing loosely mocked up, it looks pretty sweet. i cant wait to get it in the k5. thanks again in advance for the help

 

[onetonbb74]

1. search sweetk30 on here, he did a killer write up on the 205 rebuild...

2. Id open the pto cover on the side and try to see what is causing the shaft to stay in that position, if you cant move it, id grind the bottom of that lip so it sits flush into that adapter. Probably not the best thing, but my adapter is for a np208 and doesn't cover that shaft and my case has a tab that bolts to the nearest bolt to keep that shaft from spinning.

3. per my instructions for my triple stick shifters, the 203 shifter lever (closest to the 203 case) has the bolt facing toward the 203 in the bottom hole...The middle lever has the bolt facing towards the case in the top hole...and the last lever has the bolt facing the opposite way in the middle hole...

4. As for the 203 lever on the case itself, the flat lever gets removed and a ring goes over the slot and is secured by a snap ring (im sure you can just cut that lever in half and re-use it), then you use the outer lever that has the inward bend in it to the shifter heim joint, that bolt is facing away from the case.

hope that helps...

 

[GreenieK30]

When I setup a NP205, I put the idler gear, spacer, shims, shaft and bearings in a press to set the preload at @.003" then install it. Too tight and the bearing wear out fast and build heat, too loose and the gear "rattles".

The Idler shaft on the NP203 slides back and forth in the case with an o-ring on it so tap it around but don't smash the end. If you take it out there are a bunch of roller bearings and spacers that will fall out.

Trim/grind the bolt that is hitting on the shifter.

The twin stick on the 203 if for a stock t-case, on a doubler only half the 203 is used so only one shifter is used, the hi-lo-N range one.

 

[BoondocK5]

http://coloradok5.com/forums/showthread.php?t=253000

 

[sweetk30]

looks like you guys got him covered on the basics.

 

[MuddinK5]

thanks for the quick replys every1 . im just so excited about finally getting a doubler i didnt want to do anything to screw it up lol thanks again.