203/205 doubler ingredients

[orangecherokee]

Elliot that's beautiful. Nice work man. I can't wait to hear about the performance. I should have mine done too real soon. I'd also like to see your clearance issues. Keep the pics coming

[JeepsAndGuns]

One other question for ya elliott, in the pic, is the 205 clocked up as far as the kit lets you, or just slightly?

[Elliott]

Thanks Nick and yeah, I got to looking at the clocking and I just put it together like that 'cause it seemed high enough with the bottom of the 205 level with the bottom of the rest... looked like the front output would be above the crossmember under the doubler mount. It could actually go quite a lot higher, perfectly flat + from the looks of it. I want to keep the driveline angle at minimum while keeping the smooth Jeep belly line.

[4x4fEvEr]

**** way to go elliot that set up is hot! when i started this thread i had every intention of building my doubler, which i have all the parts except the doubler, you know the expensive part of the setup. but since i decided to compeletely tear my jeep down to a frame,body and engine ive run out of money and cant build mine now, so i gotta just run my 435/205 and then once i get the money go back into it. it will just cost me more to do the driveshafts twice i guess. atleast im running 60's front and rear now and 5.13 gears, i should be able to turn my 42's pretty good for now. i hope everybody else wanting a doubler gets theres built

[Desert Beast]

looks good man, im running the NWF doubler also and i love it. (well haven?t really run it yet ) but it is the best one out there imo. most adjustability and (when i bought it) the only one that had a billet intermediate shaft.

[orangecherokee]

where are you guys getting your gaskets from? NAPA, AZ, Advance, O'Reilly, etc? I need the one for the back of the 203, the front of the 203 (which is a 208 pattern) and the 205. has anyone got the PN#s?

edit: anyone used Allstategear.com? they seem to have quite the selection.

[Desert Beast]

i got all my gaskets from NWF in thier rebuild kit for the 203 and the 205.

[Elliott]

I snag gasket kits off ebay, but here's a couple sources for some of the individual gaskets, some of which are hard to come by:
http://www.quad4x4.com/New%20Process%20NP205%20Transfer%20Case.htm
http://www.drivetrain.com/transfercasesparts.html#New%20Process%20Model%2020 5

[Crazy_Jeepman]

I made my own when I did my doubler. Though I am not sure its cheaper, since gasket paper is not cheap, if you can even find it these days.

[Desert Beast]

I made my own when I did my doubler. Though I am not sure its cheaper, since gasket paper is not cheap, if you can even find it these days.

haha, ive got an old, old piece of asbestos gasket material. havent seen that for a while.

[orangecherokee]

i have a small roll of cork and a very small roll of black gasket paper. i always end up using the "blue glue" instead

which prompts this question: Do you think using the "blue glue" would be alright?

[Elliott]

I don't think you should use RTV on the housing seals as I'm pretty sure there needs to be some gap as they work as bearing retainers. I used RTV on the input retainer and it made the gear endplay too tight, unless I had another issue, but things fit right when the gasket was used. That was my experience anyway, and it was the same with the NP435 adaptor... it needed a gasket in there.
I may be completely wrong about the 205, the bearings have o-rings to keep them in the correct position in the case...

[orangecherokee]

Just ordered my gasket kit from ORD for $19. Not too bad I think. I got the 203, 205 and the PTO cover. I still need the 465 gasket but I can pick that in town.

[Crazy_Jeepman]

I still need the 465 gasket but I can pick that in town.

Yea I need to get that one too, It must be a pretty thick gasket, there is a pretty good gap between the adaptor and trans without it

[orangecherokee]

what stinks though is that I can only find the 465 set not just the one gasket. the kit at NAPA is around $25