203 crawler...Anyone done this on their own I know AA sells a kit but since I am a cheap ass I was wondering if anyone has done this at home

As far as I can tell the output shaft on the 203 could be cut down and resplined and then an adapter plate could be made, but the stock 4spd trans to 203 seems to be more difficult
Could some type of spud shaft could be used?

Any advice or pics would be helpful...oh yeh did the search

My buddy fc187 got one in his fj55 465 to 203 I'm banking it can't be much diffrent than your you having a split case is the only thing I can see. shout for him on the board & I'll talk to him today I'm sure he can tell you more than need to know (Later) JIM jb72cruz

fc has the AA kit in his.

I made a set of adapters for an NP203 doubler about a year ago. Unless you have considerable experience and the appropriate machine tools, I don't think many could accomplish this at home. An adapter plate for either the front or rear of the 203 GRB is pretty large, and to do it on a lathe requires either a very big lathe or one with a gap through the bedways. I made mine on a manual milling machine. It looked ok, but it had some alignment problems, so I never used it. The plate on the rear of the 203 needs to hold and retain the output shaft bearing and the plate on the front of the second transfer case has to hold and retain the 203 oil seal. Alignment of these two is critical and difficult to achieve for a back-yard machinist like myself. You may be better, however.

Also, it is easy to talk about shortening and cutting new splines in the 302 intermediate shaft, it is considerably more difficult to find someone to do it properly, and it is not an inexpensive matter. By the time you do all the work, buy the parts and have shafts cut and re-splined, the prices of the aftermarket shops start to look pretty good. I ended up admitting defeat, swallowed my pride and purchased the ORD adapter for the Truggy.

Jerry Nichols (colorado offroad) makes a NP203 kit for use in FJ60's with split transfer cases. Actually, I think the kit was designed by him, but is actually manufactured for them by AA.

It is sold through a few different dealers-- Mark Whatley in Alaska and Mudrak in California, I believe.

They make two different adapters-- the adapter from the FJ60 fourspeed to the NP203 GRB, and the adapter from the NP203 to the split t-case.

I am planning on using the second adapter to put a turbo350/NP203GRB/Split t-case driveline into my FJ55-- but I have not yet done it.

Everything I have heard is that it works very well.

Jared

I contacted moser and they will respline the shaft and novak will make a spud shaft but the costs are getting on up their and making the AA kit look nice maybe I can sell some stuff and just save the hassle and buy it... .anyone need rockwells, 40hood, four speed? Oh well thanks for the input

Hasn't this been talked about a few thousand times on here? Try searching here, the web, the try http://www.ih8mud.com . I looked into doing it on my 3 spd case a year or so ago but sold the cruiser.