NP203 Transfer Case Shifter Cleaning/Rebuild

[ChevyJoe]

If there is 1 thing everyone knows about the 203 case, it's the shifters always being loose and flopping around.
Decided to address it today. This is my first time doing one so please excuse the lack of proper terms

First step is to remove the hump. Mine was rusty in one corner so I had to break it off. Removing the shift lever allows it to be removed to either side.
 
I couldn't get a good picture of the bolts but there are 2 that hold it to the T Case. Most likely they are already loose.  9/16" takes them out. Lift up on the whole setup and you will see 2 levers connected to it with cotter pins. Remove these and pull it out. The levers just sit there.



Lay it on your hood ( or bench if you prefer) so the bracket is sticking up. You now need to remove the cover. I first took the large nut off since I had better leverage without the other half of the cover being loose. 5/8 and 11/16 should do it.

Next the 2 small bolts on the right side

and finally bend the tab on the left side straight and lift off the cover

[ChevyJoe]

Cover is off and this is what you should see

This is the other side. Make sure you remember the direction they came off in.
This plate and the hook under it stayed in while I pulled the other things off. You can see how much crap is in there

Remove the hook and now its time to clean. I used a lubricant spray and some rags. A gasket scraper was used for all the thick stuff. Also, I added grease to any metal parts that are touching, especially the metal pin sticking up.

Hook back in

Next put the triangle shaped plate in

[ChevyJoe]

Started snowing so I had to move inside. Not pictured but don't forget the thin washers between the triangle plate and the one above it, and then the one between the top 2. Putting the large bolt in helps to keep everything from moving around.

Clean this chrome piece. Shines up good!


This almost looks like a keychain. A hollow pin slides out of the top of the shifter mechanism and then this pulls out the bottom. Make sure you keep the long end of the spring on the square piece. When putting back in after cleaning the inside where it was, hold the shifter upside down and it will slide right in. When putting the pin in, you may need to apply small pressure to the circle side since the spring pulls on it.

Clean the housing of previous part while it's out to get anything inside of it out good.

Now the little tricky part. Have to get aformentioned pin to slide all the way down through all the plates. It was easier to move the top 2 plates onto the shifter and then slide that down onto the bottom piece.

[ChevyJoe]

Now that everything is in, you can replace the cover. I put in the 2 small bolts to hold it in place and then tightened down the large bolt. I do not know the torque specs but it was on there pretty tight. Then tighten the 2 bolts and finally bend back the tab.


So there it is, described as best I could. It feels better already and I haven't even re-installed it yet. Hope this helps anyone that needs it. If you have any questions/suggestions, please feel free to post 'em.