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there was a thread a few days ago asking about the differences between the NP 203 and the 205. Consensus seemed to be the 205 was stronger and more desirable.
I got a 203 in my 78 F-150 (135,000 miles). I've rebuilt the ford 9-inch rear, put a new engine in it, and am looking to complete the tranny and dana front end in the next year or so. But, I haven't ever heard much about rebuilding transfer cases. Since mine is a 203 (the "weaker" of the bunch),do I need to be concerned or are they pretty much mainenance free. I've had the truck about 3 years now and only put 20,000 on it, and all I could think to do to the transfer case is change the gear oil.
Actually, while I'm at it, what can I expect from the dana front end? Do they hold up well? Do I really need to rebuild it now or will it last awhile? Its not giving me any trouble so far. I just want a reliable drivetrain and just planned on rebuilding everything.
The 203 t-case is a chain drive unit ( I believe ). The procedure to check the tension on the chain is detailed in good shop manuals. If you run out of adjustment on the chain its time for a new one. If the t-case has an alumnium housing a thrown chain can break it. Bearings need attention if they are noisy or if they are loose. Once again a good shop manual will have details on how to check them. On a high milage dana 44 ball joints and steering linkages need to be checked. If you know of a good alignment shop take it in to be aligned and the tech will tell you of any parts that need replacing. Wheel bearings should be packed and adjusted on a routine basis.
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