can anyone give me any info about the shaft i need to make this work. Ive heard I can uise one of the shafts from the 203, but can someone else tell me which one, and how long i need to machine it too, and what dia.

 

check out July 2005 4wheel and offroad mag. Or go to http://www.offroaddesign.com/catalog/doubler.htm

 

there's more to it than just the shaft, there's other parts too.

 

Plenty of other parts. The only part of the 203 that you will be using is the front gear section. The rear output section ( with the chain) goes in the corner of the shop, and is now only used to collect dust, and small animals. The output shaft is the shaft from the 203 to the 205 input.(two different spline options are available) The 205 will need to be of the married type, and an adaptor used to bolt them both together. I don't doubt your machining abilities, but this is not an easy task. The kits run about $750.00 and have a few options regarding shift selectors. You will now have up to three for t-case(s) selection, not including the trans (if you run a manual).
It is a really cool way to select gear options, if you have a 203, and a 205 laying around, but can get a little bit expensive if you start from scratch.

 

The Gen2 Doubler. That's the name of the kit you need to combine the 203 range box to the 205 t case.
Like 75F350 said, the kit cost about $750, + $170-$265 for the shifters.

I have both t cases, but not the money for the adapter kit. I can do something else with $1,000(but that's b/c I don't need 4:1 low range).

 

well foget it....apparently you guys dont understand me, I am a machinist, and am making my own doubler, I have the 203, I have the 205, I know that I only need to range box for the 203, I'm not a moron, I just need to know what to look for because I do n ot know what to make the shaft out of, just looking for some suggestions or past experience

 

I am confident that we did provide you with the info you had requested. If you were looking for accurate specifications and tolerances, then that is what you should have asked for. Don't come down on us for providing you for what you asked for in the first place.

I have re-read your post, as well as the responses, and I don't believe anyone implied you were a moron.

Finding these specs will more than likely prove to be a difficult task. If manufacturers made it easy for us to duplicate their designs, they would be out of business. Buy a kit, copy it, then sell the original on e-bay, and get your money back or something. However if you calculate the time you are going to spend, on all of the research and development, (including trial, and error) you might find that buying the kit is easier, faster, and overall cheaper too. I am a moron, and I like to fab my own stuff too, but this moron was smart enough to buy the "kit" for his Ford.

Good luck.....

 

Check on http://northwestfab.com/Shifters.html They have a good setup and I will be using what they have for my 77 Highboy. One setup they have uses cable linkage so I can keep my divorced style transfercase. Just another idea you might use.

 

well I guess I'll figure something out then, thanx anyways guys. I know how to respline and turn things down on the lathe, so it should be easy I was just wondering if anyone knew of what I could make this shaft out of, like what part of the rest of the 203 will work, because i've heard that you can use some mainshaft or something.....

 

apachetech, do you mean you can actually create a dual transfer case setup with a divorced tranfer case? I looked into that theory a while ago and was eventually told it wouldn't work. I would like to keep the divorced case truly divorced from the tranny which after a bit of research I found was not possible.

 

In looking at this picture, you will see the bolt pattern for the front of the 205, and the rear section of the range box. The space in-between is to allow the spud shaft to fit. This shaft is your typical 31 spline output shaft from the transmission, only it has the other end machined to fit the rear of the range box. There is a modified pto cover to fit onto the passenger side of the box. This cover has a plug tapped into the top for fluid fill, there should also be a breather vent up on the top, too. You can easily make the gaskets for everything. Take your 205, 203, and tools, and measure what you need for making the parts. The kit form uses billet aluminum, but I assume any steel like T1, Weldox, or a611, would work. shaft should be 4150 heat treated. The idea is to duplicate each shaft end from each case, and allow the same length in the bolt-on adapter to fit. There's a seal recessed into the adapter housing, also. This seal is up to you to find which one you'll need. Couple things to think about, the linkage issue is custom, but shouldn't be too hard; the floorboard will probably have to be cut, the rubber brace holding the 205 to the frame will have to be redrilled, and the speedometer cable needs to be lengthened. Good luck.