in your opinion what a better transfer case.the 203 or 208 and why?

The 208 is the one I pick.. The main reason is the lower low range(208=2.62:1 vs 2:1 for the 203) second it is alot lighter.. by the way I have one in my 93 Dodge Cummins now that the original 205 thrashed

Paul,
203 is alot stronger. Cast iron case stands up to a lot more abuse than the aluminum 208.
But if you want to go with a 208, I've got one for you off my 85 K5 that is in great shape.
Do you still have that 10B/12B sitting beside your house? Maybe we could trade.

Brandon

Brandon,
Hey buddy,I sent you a pm.
Paul

If you want strength forget the 208, but it does have lower gearing than the 203. The 203 is a monster, one heavy sucka. The best xfer case, IMHO, is the 205, I wouldn't even mess with those other 2..........:skull:

241 the chain is bigger than the 208.

205 gear driven, no chains to stretch or break..........:skull:

203 hands down is strong. Chain is wider. 203's have an undeserved bad rep. I have 2 trucks with them. Both pushing 300K. Only thing either has ever needed was a Chain. both had the original chains in them. I just replaced one that was still full time with about 250K on it. The other was replaced by the previous owner.
Yeah they are VERY heavy cases. About 250 full of oil. If your going to run one your best to use a TH350 from the late 70's. GM made went ot a thick bell housing with a reinforced bell housing cover that hadd a set of braces the ran to the motor mounts. That housing is supose to be about 40% stronger than the old housing or a car housing.
They are a dime a dozen. Yeah the 2.6 low range is nice to have but a 203 get's you half way to a doubler. With a doubler you can got 3.96 or 2:1. as you need it.
I run one of my trucks locked in the front. The converted 203 is perfect for this. Locked means crappy steering sometimes. A converted 203 lets you run 2 low. So I just pop it out of 4wd till I need it so it will steer better. You can Modify a 205 to do the same.
All that said I may have a rebuilt TH350 (not the better housing) and a rebuilt 203 for sale soon. Looks like I just lined up a 465/205 combo. Might take me a couple months to get it in. Plan to convert to hydrolic clutch so need to get that done before I can install it.

how much thicker is one bellhousing as opposed to the other on?are there certain casting numbers on would look for?

Originally posted by ranger
205 gear driven, no chains to stretch or break..........:skull:

I have three different trucks with 208's and have not had any problems with chains stretching or breaking.. The first is a trail rig only with a 440 the second is my 86DD with 318 and the third is my 93 with the Cummins...The Cummins DID break the 205 and the 440 broke a 203 that was behind it..I am sure I will eventually break the 208 but till I do I will run it The lower low range is nice on some of the steeper stuff for the better controll...