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View Poll Results: Do want lower gears?
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Old 07-28-2008, 01:13 AM   #1
BDA
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Default Transfer case double - doubler build 203 /203 /205 w-poll

So we were talking about gear ratios and how low is "low enough" one day, and that got me to thinking what I really wanted out of my truck in low range. I did not ever want to think "wish I had lower gears" EVER. So ...

I called Northwest Fab and they fixed me right up - for a mere $1,400

Here is how it went:

Basic 203/205 doubler kit (with Fig 8 - 205 plate)
I ordered this AND an Atlas/203 doubler kit
The Atlas kit has an adapter flange that fits on the face of a 203 with minimal mods. It is used to put the 203's together.
Name:  NWF doubler 026.jpg
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New billet NW Fab 32 spline output shaft
Name:  NWF doubler 022.jpg
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To build the 203 range box pull off the chaincase and tail housing, save the bearing, gear, spacer, pin, snapring.

Assemble bearing into the 203 cover plate
Name:  NW Transfercase double build 009.jpg
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New shaft with pin, spacer, and gear
Name:  NW Transfercase double build 011.jpg
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Assembly with new shaft through the 203 plate and bearing.
Name:  NW Transfercase 203 adapter.jpg
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Building - 76 Chevy 1 ton 4 door
2 Rockwell Steering axles,
Stroked 454,TH-400,
NP-203 / 203 / 205 Tcase Doubled Doubler
Full hydro steer,
Coilovers front and back,
53" Tractor tires on 24" wheels
It's NOT Junk if you Know what it's For

Last edited by BDA; 07-28-2008 at 09:53 PM. Reason: Forgot whole bunch of good stuff
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Old 07-28-2008, 01:31 AM   #2
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

Name:  NW Transfercase double build 017.jpg
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203 Range box with NW Fab adapter plate installed

Name:  205 Transfercase build 008.jpg
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Adapter plate with indexable extension tube

Name:  Transfercase 203-203.jpg
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203 range box with adapter plate, tube, and Atlas adapter plate used to put 2 203's together.


Name:  Transfercase 203-203 1.jpg
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203 range boxes as they would be put together

Name:  Transfercase 203-203 2.jpg
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__________________
Building - 76 Chevy 1 ton 4 door
2 Rockwell Steering axles,
Stroked 454,TH-400,
NP-203 / 203 / 205 Tcase Doubled Doubler
Full hydro steer,
Coilovers front and back,
53" Tractor tires on 24" wheels
It's NOT Junk if you Know what it's For
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Old 07-28-2008, 01:33 AM   #3
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

dang...1400?? oh thats basically for 2 doubler kit huh?? I got mine from them and I love it... I actually have never drove over anything that 4-1 wasnt low enough for....maybe your a lil more hardcore than me though... keep the pics coming...sounds cool...3 gearboxes !!!
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Old 07-28-2008, 01:47 AM   #4
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

The 203 bearing retainer must be turned down so that the Atlas plate will fit over it. The bolt holes must also be counter sunk and the bolts ground down on both ends.
Name:  Transfercase seal retainer countersink.jpg
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Shorter bolts
Name:  Transfercase shorter retainer bolts.jpg
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Drill and tap the 203 box to accept the Atlas adapter bolt patern
Using flat bar with hole for a drill guide to keep hole square.
Name:  Transfercase 203 drillntap.jpg
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Atlas adapter plate bolted up to the 203 range box
Name:  Transfercase 203 203 plate.jpg
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203 with 205 and Atlas plate - ready for the other 203
Name:  Transfercase 205-203.jpg
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Size:  29.0 KB
__________________
Building - 76 Chevy 1 ton 4 door
2 Rockwell Steering axles,
Stroked 454,TH-400,
NP-203 / 203 / 205 Tcase Doubled Doubler
Full hydro steer,
Coilovers front and back,
53" Tractor tires on 24" wheels
It's NOT Junk if you Know what it's For

Last edited by BDA; 07-28-2008 at 09:58 PM.
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Old 07-28-2008, 01:58 AM   #5
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

205 mounted to the 203 with atlas plate
Name:  Transfercase 205 with plate.jpg
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Size:  33.7 KB

205 with adapter plate and index tube ready for 203
Name:  Transfercase 205 with adapter.jpg
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Size:  36.6 KB

203-203-205 together with TH-400 tranny mount 32 1/2"
203's are mounted in normal orientation, 205 is clocked up 4"
Name:  Transfercase 203-203-205 3.jpg
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Size:  36.8 KB

Back side 203-203-205
Name:  Transfercase 203-203-205.jpg
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Size:  32.1 KB

Name:  Transfercase 203-203-205 1.jpg
Views: 9837
Size:  34.9 KB
__________________
Building - 76 Chevy 1 ton 4 door
2 Rockwell Steering axles,
Stroked 454,TH-400,
NP-203 / 203 / 205 Tcase Doubled Doubler
Full hydro steer,
Coilovers front and back,
53" Tractor tires on 24" wheels
It's NOT Junk if you Know what it's For
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Old 07-28-2008, 10:15 AM   #6
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

WOW :-O I can't wait to see how it all turns out!
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Old 07-28-2008, 11:03 AM   #7
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

what the gear reduction just through those? What will you end up with as a crawl ratio?
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Old 07-28-2008, 11:03 AM   #8
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

what is the final reduction in that?
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Old 07-28-2008, 11:13 AM   #9
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

Holy crap...you'll never see 4 low in anything we have here...Nice write up...thanks
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Old 07-28-2008, 01:17 PM   #10
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

Nice multiplier!
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Old 07-28-2008, 03:46 PM   #11
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

should be 2.48 in transmission 1.96 in the 205 1.96x2 in the 203s and of course the torque converter 2 then axle but don't know that just yet. so 2.48x2x1,96x1.96x1.96=37.34to 1 before the axle and if this is for the 2 1/2 tons the the axle would be 6.72 it would come out to 250.96 to1 witch is a holy low gears batman!!!
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Last edited by subranger; 07-28-2008 at 09:40 PM.
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Old 07-28-2008, 06:25 PM   #12
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

Quote:
Originally Posted by subranger View Post
should be 2.48 in transmission 1.96 in the 205 1.96x2 in the 203s and of course the torque converter 2 the axle but don't know that just yet. so 2.48x2x1,96x1.96x1.96=37.34to 1 before the axle and if this is for the 2 1/2 tons the the axle would be 6.72 it would come out to 250.96 to1 witch is a holy low gears batman!!!
Yeh - what he said. Thanks Ranger, just got home.

I shifted it on the bench with tape for markers on the input and output - 8:1 basically for low-low-low.
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Building - 76 Chevy 1 ton 4 door
2 Rockwell Steering axles,
Stroked 454,TH-400,
NP-203 / 203 / 205 Tcase Doubled Doubler
Full hydro steer,
Coilovers front and back,
53" Tractor tires on 24" wheels
It's NOT Junk if you Know what it's For
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Old 07-28-2008, 07:48 PM   #13
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

That is **** near retarded! Retards are slower.
This would be great for ......I don't know what.
I think your going to find the weak link quick.
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Old 07-28-2008, 09:23 PM   #14
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

Well, I never claim to be a mental giant -
as for speed - haste makes waste.

I will be able to shift each individually so I will not sacrifice top end, with one or both 203's in "high" they will be 1 to 1, so no gear reduction.

Weak link? - Ah yes, the sooner the better.
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Building - 76 Chevy 1 ton 4 door
2 Rockwell Steering axles,
Stroked 454,TH-400,
NP-203 / 203 / 205 Tcase Doubled Doubler
Full hydro steer,
Coilovers front and back,
53" Tractor tires on 24" wheels
It's NOT Junk if you Know what it's For

Last edited by BDA; 07-28-2008 at 11:56 PM.
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Old 07-28-2008, 10:06 PM   #15
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

The cable shifters are next (4),
- and the cradle for the cases to mount in the frame,

- Does the cradle for the T-cases need to include a mount for the transmision to eliminate torque on the case bolts????
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Building - 76 Chevy 1 ton 4 door
2 Rockwell Steering axles,
Stroked 454,TH-400,
NP-203 / 203 / 205 Tcase Doubled Doubler
Full hydro steer,
Coilovers front and back,
53" Tractor tires on 24" wheels
It's NOT Junk if you Know what it's For
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Old 07-28-2008, 10:14 PM   #16
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

Quote:
Originally Posted by BDA View Post
The cable shifters are next (4),
- and the cradle for the cases to mount in the frame,

- Does the cradle for the T-cases need to include a mount for the transmision to eliminate torque on the case bolts????

No. If the t-cases are mounted well, there is no need for a tranny mount.
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Old 07-29-2008, 12:02 AM   #17
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

I would errr on the side of caution in this instance. But hey, what do I know. I never even seen this stuff before. Honest!
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Old 07-29-2008, 01:56 AM   #18
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

****, how long is the rear drive shaft going to be? shorter then the front...... with triple low you can ghost ride it love the blue metal flake paint job
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Old 07-30-2008, 02:29 PM   #19
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

was thinking about your build up and being that all your t-cases have the same gearing you have over laps in your gear ranges. you have 1to1 2to1 4to1 or 8to 1 not bad. but lets just say that you get the lowmax 205 you would be able to do 1to1 2to1 3to1 4to1 6to1 and 12to 1. you would be able to pick from all kinds of gearing options for the right terrain. just a thought
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Last edited by subranger; 07-30-2008 at 02:32 PM.
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Old 07-30-2008, 04:58 PM   #20
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

lol... I think 8to1 is more than low enough... I was thinking about puting the lowmax in my 205...so I could have 6to1....but then again.. Ive never found anything that I couldnt get through in 4to1....
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Old 07-30-2008, 09:20 PM   #21
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

Quote:
Originally Posted by anchak508 View Post
lol... I think 8to1 is more than low enough... I was thinking about puting the lowmax in my 205...so I could have 6to1....but then again.. Ive never found anything that I couldnt get through in 4to1....
i think your right 8toi is more than low enough. but what i was getting at is for all the other options that you could get with the lowmax. but it the end it's not mine heck i still don't even have a doubler let alone a trippler lol
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Old 07-30-2008, 11:57 PM   #22
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

With 53" tires, 8 to 1 will work great. Crawling through the swamps will be easy. Most people here have never wheeled with 'big' tires before.
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Old 08-03-2008, 07:25 PM   #23
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

I haven't either......I better get down to the garage and get back to work. Christ! Drilling them hole is going to be a ***** with the buZz I have right now.
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Old 09-02-2008, 12:33 AM   #24
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

Finally got the sight glasses and covers back on the cases.
I wanted to be able to easily check fluid level and contamination

-Tried clear tubing with fancy fittings, But Murphy would have surley torn them off.
-Tried Plexi on the outside of the cover, but Murphy would have cracked the plexi.
-So I took a "bling" cover and milled a big slot in it, drilled a fill hole in the corner, and sandwiched the plexi inbetween the cover and t-case.
-I also made a cover for the 205 as NWF only sent 2.

NWF cover
Name:  NWF doubler 023.jpg
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Modified cover with plexi window
Name:  Transfer case sight glass 001.jpg
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Cover installed with plexi behind it - easy gear inspection too
Name:  Transfer case sight glass 004.jpg
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All 3 installed
Name:  Transfer case sight glass 003.jpg
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Size:  29.9 KB

Next is the cradle
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Building - 76 Chevy 1 ton 4 door
2 Rockwell Steering axles,
Stroked 454,TH-400,
NP-203 / 203 / 205 Tcase Doubled Doubler
Full hydro steer,
Coilovers front and back,
53" Tractor tires on 24" wheels
It's NOT Junk if you Know what it's For

Last edited by BDA; 09-02-2008 at 12:39 AM.
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Old 09-02-2008, 10:16 AM   #25
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Default Re: Transfer case double - doubler build 203 /203 /205 w-poll

thats cool...wish I would have thought of that with my doubler....
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83' Chevy CUCV Camo
39.5 Iroks
LQ4 6.0
TH-350-203-205 triple stick
d60 Highsteer, 14bff Detroit and discs
warn 9.5xp

05' Silverado
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