What happens if chain breaks in NP203?

My '79 Power Wagon has the NP203 transfer case, and everything works well. I like to plan ahead, so I've researched and found that it seems everything except the chain is available for a rebuild.

What would one do if the chain broke? I can't find them from any source for the 203 or 205. Has me kind of concerned.

Thanks,

Larry

drivetrain.com shows 2 different ones-73-78 and 78/79. difference is in width(2.0 or 2.5) and pins( 72 or 98) and pitch(3/8 or 1/2 inch). about 150.00.

The 203 and 205 transfer cases don't have a chain. But I've never seen a broken transfer case chain in the ones that do have one.

How are you going to manage breaking a chain that's 2.5" wide. If you aren't driving big foot I wouldn't worry about it.

Well then people should stop putting chains in them!

Yes they should! As I understand it the 205 is the part time TC, the 203 is the full time version. Both are cast iron cases and are gear to gear, no chain. The aluminum case ones have a chain but I don't know all the different model numbers. Speaking strictly for the New Process cases only, lord knows what else is out there.

A rebuilder of the NP203 and 205 who is supposed to be the guru of these responded with this:

"you have a 203, great cases till they mess up. most parts still avaliable except chains.
you can put a part time kit in them 2 make 2 wheel drive.
if you go with a 205 like i have advertised you will have to have your tranny rebuilt with a longer output shaft"

So he rebuilds these by the dozens and doesn't know they don't have chains? And drivetrain.com indicates chains? What gives?

Stumpy, high mileage truck. Just like everything else, they can stretch, and break. It does happen.

My mistake. I am not familiar with the 203 but some exploded views do show a chain. The 205 does not have a chain.

79 W-150's, 203 case does definitely have a chain and as all chains, will stretch. My original truck has 110,xxx miles on it and is stretched as indicated by a resounding "clunk" when putting in drive or reverse...no other ill effects to date.
Here's a pic of the chain/case taken during the resto. on my Warlock a couple of years ago: BTW it had 120,xxx on it, same thing "clunk", but no other problems... We were able to find a chain for it at that time.

Thank you 4x4 Roundup. Looks great after resto!

Do you know if they go by number of links as to what fits? I'm wondering if Chevy, Ford, Dodge all use same chain if they have NP203. Thanks.

Larry

Don't know, but will find out in a few days.

Here's a scan from the parts book.

Perfect!!! Thank you so much for scanning that!!! Just what I needed!!!

Roundup, do you know if '79 W150 would have 2" or 2.5" chain? Thanks again.

Larry

Major difference between stretch and break.

as i said in post above, chain is determined by year, width, pins and ,for lack of a better term pitch, either 3/8 or 1/2 inch. there used to be a kit that you could put in the 203 that was an eccentric type fit in the case and you could rotate it sightly to take stretch out of chain. haven't seen one in years though.

I listed my year, 79. I thought maybe all '79's were 2" despite some other variables. I am searching with part number 4x4 Roundup listed, but haven't found width yet. I saw pitch nomenclature in part numbers pdf he listed.

The NP203 uses a chain and the NP205 uses gears.

Check this out:

https://www.ebay.com/itm/NOS-MOPAR-4115334-74-79-Dge-4X4-chain-transfer-case/293360987390?_trkparms=aid%3D111001%26algo%3DREC.SEED%26ao%3D1%26asc%3D20160908105057%26meid%3D36808e8e36ad45ceb42af7cf7a0b5b23%26pid%3D100675%26rk%3D2%26rkt%3D15%26sd%3D164005218
and:
705%26itm%3D293360987390%26pmt%3D0%26noa%3D1%26pg%3D2380057&_trksid=p2380057.c100675.m4236&_trkparms=pageci%3A257fe30f-280f-11ea-875b-74dbd1807b82%7Cparentrq%3A43824d4d16f0ad4a7688deb0ffb8e74e%7Ciid%3A1

or:
https://www.ebay.com/itm/NOS-NP203-2-Inch-Morse-Transfer-Case-Chain-Hy-Vo-HV009-New-Process-203/293387821212?epid=626914143&hash=item444f46e09c:g:8YEAAOSw14Zd~rLT

Personally I would not attempt to buy one until I saw which one the truck has in it...you know how these trucks were built.

Sorry the links do not seem to work, just go to e-bay and put in the part #'s. The ad with the morse chain has some information about the different chains etc.

To make ebay links work leave everything off of the address after the ?.
https://www.ebay.com/itm/NOS-MOPAR-4115334-74-79-Dge-4X4-chain-transfer-case/293360987390?
https://www.ebay.com/itm/NOS-NP203-...y-Vo-HV009-New-Process-203/293387821212?

Thanks. I didn't see the first one but have been messaging the seller of the second one since last night. Seems knowledgeable. His is a 2" chain that's why I was asking if anyone could confirm mine was 2". He stated I would need different gears if mine is 2.5". If I'm going to have this in storage for future, I want to have right one. Gears appear to be available now but I don't know about future and don't want to buy new 2" gears right now to store as well if I don't need them.

I snagged the Morse chain. Peace of mind. The 2" chain is a stronger setup due to it's greater pitch (1/2" vs. 3/8" on the 2.5" chain).

I had a 79 W-150 w/203 and the chain had got worn and would make a popping and banging noise like it was climbing the sprockets toward the end of its life

The transfer cases would have a metal tag with the part number on them, maybe yours is still there.

Oh, good I'll check!