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203/205 Transfer case slop

white-rhino

white-rhino

Older than dirt
Joined
May 19, 2020
Member Number
154
Messages
703
Loc
Michigan but not in Detroit
When I had an Atlas in my YJ I experienced chatter in the transfer case when decelerating or unloading the drive line. It sounds like most people experience this. I bought a rig with a 203/205 combo and WOW is it noisy when it's unloading. Driving on pavement in 4wd didn't seem bad but when driving on a rough gravel road it was terrible. YES - there are now 2 cases to rattle and chatter but I would have assumed that a OEM case would not rattle like this.

Is this normal with a 203/205 combo?
 
Not normal.

The 203 box is a counter shaft style so you could be needing to re bearing it.

The 205 uses taper bearings for the intermediate shaft and may need to shim or redo that aswell.

I beat the fuck out of my 203/2052so hard i wiped out my 465. Not a peep out of the cases.

Worn bearings wll allow excessive gear lash and slop.
 
Single or double cardan driveshafts? How much angle on the driveshafts?
 
total newb said:
Not normal.

The 203 box is a counter shaft style so you could be needing to re bearing it.

The 205 uses taper bearings for the intermediate shaft and may need to shim or redo that aswell.

I beat the fuck out of my 203/2052so hard i wiped out my 465. Not a peep out of the cases.

Worn bearings wll allow excessive gear lash and slop.
Click to expand...

Well that's not what I wanted to hear. LOL
 
77K5 said:
Single or double cardan driveshafts? How much angle on the driveshafts?
Click to expand...

Single front and rear. Front has double shaft with carrier bearing. Rear has "some" angle but would have to check. Front is pretty good. With that said, the front pinion is tipped up towards the carrier bearing and I've noted that the shafts are not parallel. That could be part of the problem.
 
total newb said:
203 is a pretty easy job. 205 is a bit harder
Click to expand...

Bigger project is getting them in and out. Gawd are they heavy. The buggy is packaged pretty tight. I just had them out for a trans swap and looked at the gears through the cover plates and they looked great. (actually maybe only the 205, I don't think there was a visual access on the 203). I changed the oil and the old oil coming out didn't have any residue or sparkles. Either way, I'm gonna run it this weekend and see how it does. I'm hoping it was magnified by the washboard gravel road I was on.
 
Bringing this back up, other things have occupied my time. I've done everything BUT pull the transfer case. Both front and rear pinions were tipped up towards the case & being single cardan, I figured this would be my problem. So I rolled them both down to an acceptable parallelism and also put new driveshafts in. (front slip spline was sloppy) Rear was upgraded from 1350 to 1410 for better angle clearance. Results are better but not satisfactory.

I just came to the conclusion that I have .010 -.011" endplay in my rear output. Reading this from the other site, it doesn't seem to be a big deal but I would like to fix it.
www.pirate4x4.com

Np205 output shaft play

www.pirate4x4.com www.pirate4x4.com

Can the rear ball bearing be replaced by just pulling the rear bearing retainer housing and not having to pull or open the case?
 
Its not the end of the world. Just need to recover them and it can be messy.

They are .180" diam ish so its easy to find if youre missing one. Worst case you have to take the rear cover off ans sneak them out the bottom.
 
total newb said:
Its not the end of the world. Just need to recover them and it can be messy.

They are .180" diam ish so its easy to find if youre missing one. Worst case you have to take the rear cover off ans sneak them out the bottom.
Click to expand...
As long as I don't have to pull the case.......... Pulling the case means skins, seats, floors, exhaust, linkage, etc. Not a fun project. I'm gonna look up an exploded view now to better understand it.
 
did this ever get solved. i was breaking in front gears last night and letting off the gas i notice a lot of chattering, but if i ride the brake a tiny bit it all goes away. so something inside feels alittle loose
 
so i did this. i forgot a bearing last spring. installed it. but maybe driving in only front wheel drive and rear just coasting is it possible i dont have a washer inside here. hmmmm inquiring minds want to know. :lmao::lmao:

 
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