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Dual Transfer Case Adaptor Kit 
Before beginning to install your twin transfer case adaptor, unpack the shipment and make a checklist that the following parts are not missing. If you fail to locate any of these parts, contact NorthWest Fabworks immediately. Part Checklist: One 203 adaptor plate One Center Index ring One 205 or Dana 300 adaptor plate One 8620 Billet Intermediate Shaft Two Large O-rings Brass Breather fitting One PTO Cover /w Fill Plug Eight 3/8”-NC x 7/8” Bolts Four 3/8”-NC x ½” Button Head Cap Screws Eight 3/8” NC Nuts Eight 3/8” lock washers Eight 3/8”x2” Studs In addition to this checklist you will also need: One NP203 Range Box One NP205 with female 32 (short) or 31 spline input gear. Two 9/16” Combination Wrenches One 9/16” Deep socket and Socket Wrench One GOOD pair of snap ring pliers Imperial Allen Key Set Needle Nose Pliers Transmission Jack ______________________________________________________________________________ Step 1: Remove NP203 from transmission if necessary ______________________________________________________________________________ Step 2: Drain all oil from NP203 into a container and discard/recycle where safe.  ______________________________________________________________________________ Step 3: Separate tail housing from chain case. This is done by removing the 6 bolts that hold the tailhousing to the chain case. After the bolts have been removed, smack the housing with a deadblow hammer to loosen the seal. ______________________________________________________________________________ Step 4: Pry tail housing away from chain case. You will now see the shift fork assembly.  ______________________________________________________________________________ Step 5: Using small punch drive roll pin out of shift fork  ______________________________________________________________________________ Step 6: Unbolt range box from chain case and separate. There are 8 bolts holding the range box to the chaincase; 6 acessed from the front of the range box, 2 from the backside.  This may require a light tapping or wiggling on the chain case to break the gasket seal. Once you have the cases seperated about 1" you will notice a rod hooked from the range box onto the rear shift rail. You will need to unhook this rod. Once you have, you can now lift the chaincase up and away from the range box. This may require some wiggling to free. At this point you can discard of the chain case and the aluminum tail housing as they are not required to complete the doubler installation  ______________________________________________________________________________ Step 7: You will need to remove the portion of the NP203 shift linkage that connected to the rear shift fork earlier in disassembly. This can be found inside the range box.  If you do not remove this, it could potentially fall into your range box and cause serious damage to your gears. ______________________________________________________________________________ Step 8: Make sure you have a clean and uncluttered section of work area, often placing cardboard or newspaper down is a good plan. 
Remove the low range gear and intermediate shaft assembly by pulling it straight out of the range box, and place the assembly on the workbench. **Note** inside the low range assembly contains 15 fat needles, these MUST be accounted for, and often fall inside the NP203 range box. You will need these needles later in the installation of your adaptor kit. If you do not retrieve all needles from the 203 range box, they could get caught between gears and cause serious damage. Collect the needles and put them aside, in a clean container or bag. ______________________________________________________________________________ Step 9: You now need to separate the low range gear from the stock intermediate shaft  This is accomplished by removing the snap ring retaining the bearing to the shaft. You will need a LARGE set of snap ring pliers. Do NOT use small snap ring pliers, you will snap them and injur yourself in the process. Extra care must be taken as this snap ring can pop violently when removed. Wear eye protection! Set the snap ring aside, you will need it. ______________________________________________________________________________ Step 10: Remove the factory roller bearing and bearing retainer by pulling vertically along the mainshaft. You will then need to remove the thrust washer that is located below the bearing and retainer. Often the gear oil makes this thrust washer stick to the roller bearing assemby. Clean the thrust washer and set it aside, you will need it. With a set needle nose pliers, remove the locating pin found on the shaft   These are the parts you will need to keep for the re-installation of your low range gear and billet mainshaft. Don't forget the locating pin! ______________________________________________________________________________ Step 11: Check that the roller bearing in your factory bearing retainer (removed in Step 10) is still good. these transfer cases are over 25 years old, there is a good chance it is no longer useable. If this is the case, contract NorthWest Fab for a replacement. If the bearing is still in good working condition, remove the bearing from the factory retainer: This is accomplished by removing the large snap ring, and pushing the bearing out from the backside of the retainer. ______________________________________________________________________________ Great! Your Done This Disassembly of the NP203 range box! ...Now To Put It All Back Together :) Now Head Onto Page Two! | |
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