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This picture might explain the synchro and locking on the gear.

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image-2826842510.webp
 
This picture shows what you are working with.
You can see the small thooth on the side of the gears and the conic rim next to it.
The small gear has an opposite conic inside that together works as the syncronising system.
When this has brought the speed of the two gears to the same speed the collar shifts over and lockes the gears together.
The tiny parts on the side are the locking tabs. They actualy lock the gears together until you shift them out.
I hope this helps you to understand where to look for your problem.

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image-2628069945.webp
 
Have you tried shifting the 203 with the TC in neutral and the engine running with the trans in drive?
If you didn't you should try this.

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waiting for time said:
Have you tried shifting the 203 with the TC in neutral and the engine running with the trans in drive?
If you didn't you should try this.

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Click to expand...

it'll grind.. why do you want him to do this?
 
Mace said:
it'll grind.. why do you want him to do this?
Click to expand...

If the synchro is not able to syncronise the speed of the trany with the speed of the wheels it might be easyer to syncronise the speed untill the TC. There is much less weight to slow down or in this case speed up. Doing it this way he can determine if the problem is in the gears or in the shifting mechanism.
I don't think it will grind as long as he shifts slowly allowing the synchromesh to do its job.

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It does not work that way..

Without the tranny in park, or the motor off (and I'm serious about the motor being off) the tailshaft will spin, and the rangebox will just grind away, never hitting a gear.
 
Mace said:
It does not work that way..

Without the tranny in park, or the motor off (and I'm serious about the motor being off) the tailshaft will spin, and the rangebox will just grind away, never hitting a gear.
Click to expand...

This is correct!
I had tried different combinations trying to get it to engage with The rig running.
It HAS to engage without the tail shaft of the trans spinning.
I sent an e mail to mudrak hoping that he might know a bit more about trouble shooting complications with the 203. There isn't really that much to fail in them. I've searched... There is surprisingly little I could find on the topic as it is.... Dealing with just the range box. Most issues surround the complete using and shift links on that.
 
Btw... Just for clarification... Unless it's the link arms binding, there is actually no way for the shifters to not throw all the way. I say this, because if I were to take off the whole bracket that the levers are on I could rotate em 360 deg.

I'm just gonna have to pull the cases out and see and give it a good check on the bench.

I appreciate all the thoughts on this!!!
 
Kieth-Likely not helpful, but I have a 203 in the garage that I could look in and take pictures over the weekend if that would help. I'm probably willing to part with pieces of it too, if you need them. The fork and shifting mechanism works fine on the bench, so I don't know if that would be helpful or not.

If you want to drive down to Sac, you can take it back to Reno for side by side comparisons.
 
I added some leds to the top of my cage to act as a done light and some red and blue strobes.

Can't help ya with your cases sorry.

Sent from my DROIDX using IH8MUD
 
Cruiserdrew said:
Kieth-Likely not helpful, but I have a 203 in the garage that I could look in and take pictures over the weekend if that would help. I'm probably willing to part with pieces of it too, if you need them. The fork and shifting mechanism works fine on the bench, so I don't know if that would be helpful or not.

If you want to drive down to Sac, you can take it back to Reno for side by side comparisons.
Click to expand...

Andy,
Thanks man!!
I would greatly appreciate any pictures and your thoughts on how the mechanism works inside the box and potential causes for what I'm experiencing.
If I don't have to pull these boxes cometely out it would make life a ton easier. I could get the gasket for the leak on w/o pulling em out of the rig.

Thanks for the offer!!!
 
LCOwner said:
I have nothing to add but this is funny. I understand why he included it. This thread needs a good laugh lately. Hope you get it figured out Chi.
Click to expand...

Lol!!! Didn't notice that!!!
That is funny!!

Thanks man. It'll work out!
 
Ok put it in high and do jumbo tomarrow maybe if you give it some exersize it will play nicer

It could be angry from sitting in the garage to long
 
RAYJON said:
Ok put it in high and do jumbo tomarrow maybe if you give it some exersize it will play nicer

It could be angry from sitting in the garage to long
Click to expand...

I had actually thought about doing that!!!
However, the temp gauges are non op for some reason, and I dont wanna wheel w/o those working.
 
So I gave mudrak a call today per Georg's recommendation to discuss this a bit and get his take. He seems to think that assuming everything is set up right, it might need a bit more leverage on the handle, or just technique in the shifting. He recommended trying to find high with the rig moving slowly in either forward or reverse. He admits that he had never done on of these w/ an auto, but he said that even with a manual, they can be hard to get into one gear or the other.
 
LCOwner said:
I have nothing to add but this is funny. I understand why he included it. This thread needs a good laugh lately. Hope you get it figured out Chi.
Click to expand...

Thanks it's my IPhone sig line :lol:

sent from outer space via my mind
 
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