swapping input gear on 203 help

[muddybuddy]

ive currently got 32spline 203 infront of my doubler, but i need to swap it to 27spline. ive got the new input for it, but do i have to take the whole range box apart to swap the input, or can i swap it w/o taking the whole case apart (by removing the allen head bolts and taking the input seal/bearing out and doing it from the front of the case). im asking because the doubler is all together, so if i could avoid tearing it all down that would be less hassle. if i have to take it completely apart should i get a new doubler adapter gasket? thanks

 

[4X4HIGH]

ive currently got 32spline 203 infront of my doubler, but i need to swap it to 27spline. ive got the new input for it, but do i have to take the whole range box apart to swap the input, or can i swap it w/o taking the whole case apart (by removing the allen head bolts and taking the input seal/bearing out and doing it from the front of the case). im asking because the doubler is all together, so if i could avoid tearing it all down that would be less hassle. if i have to take it completely apart should i get a new doubler adapter gasket? thanks

The range box needs to come completely apart. You can remove the input bearing from the front but the shaft and gear are one piece and must come out the back.

 

[muddybuddy]

alright cool, thanks scott. i had a feeling that was what needed to be done.

you think i would be able to reuse the doubler adapter gasket and put rtv sealant on it or should i get a new gasket?

 

[4X4HIGH]

There's nothing wrong with reusing the old gasket as long as it doesn't tear coming off. Just remember this though, it's ALOT of work to have to change it later should it leak.

 

[muddybuddy]

well i finally got around to pulling the doubler apart to swap the 27spline input in, but it wont come out. is the bearing pressed onto the input? i can move the input in and out about 1/2" but cant move it any farther. i removed the snap rings on the input between the bearing and input shaft, but put the snap ring back on the outside of the bearing to the housing. is the input gear supposed to just slide right out into the inside of the case? maybe these pics will help a little. am i missing anything? should i be able to hit the input out with a brass hammer or something?

 

[4X4HIGH]

It is not pressed on. The input gear may be moving back and hitting the shift fork. You might have to remove the shift fork. You can also try to move the shift fork in such a position so the input gear doesn't hit it when trying to remove it.

Looks like you've got one of the old wagoneer machine 3.0:1 gear sets in there?

 

[tRustyK5]

What is with the welded gear in there? That doesn't look factory...

Rene

 

[muddybuddy]

It is not pressed on. The input gear may be moving back and hitting the shift fork. You might have to remove the shift fork. You can also try to move the shift fork in such a position so the input gear doesn't hit it when trying to remove it.

Looks like you've got one of the old wagoneer machine 3.0:1 gear sets in there?

thanks for the help man. the shift fork doesnt actually hit the gear, the gear really only moves forward, but i cant really push it back into the case to pull it out. but ive got everything removed so it should slide out right? no more hidden snap rings or anything?

yea good eyes, its a wagoneer 203 rangebox, its brand new, never been run before. its got 32spline input cuz i was originally going to run a 4L80E, but im going to just stick with my 700r4. should make for a nice 4spd doubler

 

[muddybuddy]

What is with the welded gear in there? That doesn't look factory...

Rene

those are the welds from WMS for the bigger gear set. you can also see here where the housing has been modified as well for the bigger gear.

 

[4X4HIGH]

If everything is out of the way then you might need to hit the input gear with a rubber mallet. The only thing that would stop it from coming out once everything behind it is removed would be the snap ring on the input gear just in front of the bearing. The large snap ring on the OD of the bearing just keeps the bearing from moving inwards when everything is assembled. You could remove that snap ring and just remove the input gear and bearing as an assembly and then deal with removing the bearing from the shaft after it's out.

 

[twoslo4five0]

we had to change my doubler from a 23 spline to a 27 but i couldnt tell you how to do it..i had alot of help with it

 

[muddybuddy]

i got it out, the rubber mallet did the trick, but im probably going to have to remove the shift fork to get the input all the way out.

 

[muddybuddy]

well looks like im going to be staying with 32spline...check out the difference between the WMS 32spline input gear (right) and the standard 27spline input gear (left), definitely wont be able to just swap them out. looks like it time to look for a th400 or 4L80E again what a PITA

 

[4X4HIGH]

Hmm, i wonder if they used gears from a 203 and 205 and machined/welded them to come up with the 3:1 set. Maybe the 205 input gear is the correct diameter? Anyone here that can verify if a 203 and 205 input gear is just a matter of different size OD on the gear and all other aspects of the input are the same? Just a thought.

 

[muddybuddy]

Hmm, i wonder if they used gears from a 203 and 205 and machined/welded them to come up with the 3:1 set. Maybe the 205 input gear is the correct diameter? Anyone here that can verify if a 203 and 205 input gear is just a matter of different size OD on the gear and all other aspects of the input are the same? Just a thought.

that could be a possibility hmm. my 700r4 has been through alot and probably needs a rebuild anyways, but itll work for now. ill just get the doubler back together and run the 208 in the truck for now til i can get everything figured out.