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Old 05-23-2012, 04:30 PM   #1 (permalink)
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203/205 doubler noise?

Hi,
I have a divorced ford 203/ 205 doubler that I built with a NWF doubler kit. After my first test ride, i noticed a really bad "gear chatter" noise coming from the 203. The noise would get worst with increased speed. It would make the noise with the 203 in hi, low and neutral. I pulled the doubler and tore the 203 apart, but i couldn't find anything wrong inside. any ideas? i'm stumped
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Old 05-23-2012, 06:23 PM   #2 (permalink)
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Hows your pinion angle?
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Old 05-23-2012, 07:21 PM   #3 (permalink)
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pinion angles are pretty shallow, it makes the noise with the 203 in neutral; so i think i've ruled out driveshafts.
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Old 05-24-2012, 12:54 PM   #4 (permalink)
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what fluid you have in there? both cases full?
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Old 05-24-2012, 01:12 PM   #5 (permalink)
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Mine does the same thing in a neutral load situation.
Meh, been doin it for +2 years, still workin fine.


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Old 05-24-2012, 03:10 PM   #6 (permalink)
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i'm running regular gear oil in the 203 and 205. I have an odd offset angle on the drive shaft feeding the 203, i think it may be vibrating causing my gear chatter sound.
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Old 05-24-2012, 03:11 PM   #7 (permalink)
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and the gear oil is 80w-90w
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Old 05-24-2012, 05:03 PM   #8 (permalink)
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i'm running regular gear oil in the 203 and 205. I have an odd offset angle on the drive shaft feeding the 203, i think it may be vibrating causing my gear chatter sound.
Uh, why do you have an offset angle on the stub shaft.
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Old 05-24-2012, 06:21 PM   #9 (permalink)
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Uh, why do you have an offset angle on the stub shaft.
very simple, i screwed up when i measured for my mounts on the doubler. once i realized it, the truck was together; so i drove it to see if it was a problem.
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Old 05-24-2012, 06:32 PM   #10 (permalink)
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here is a picture, its kinda hard to tell. but the doubler is offset about an inch off of the center-line of the transmission; towards the driver side

Last edited by s10mk; 05-24-2012 at 06:36 PM.
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Old 05-24-2012, 07:44 PM   #11 (permalink)
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very simple, i screwed up when i measured for my mounts on the doubler. once i realized it, the truck was together; so i drove it to see if it was a problem.
Well since you cant run with the chatter than it evidently is a problem with the doubler mounting location. Either mod your existing crossmember or build a new on..

Im curious as to why you took the whole thing apart, put it back together, and stuck it back io the same off center crossmember???
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Old 05-24-2012, 07:53 PM   #12 (permalink)
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I don't know how it would work with a doubler, would the 203 and 205 share the same fluid?

I only ask because I thought 203's were supposed to use 30w , does that not matter with the back half gone?
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Old 05-25-2012, 05:11 AM   #13 (permalink)
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I only ask because I thought 203's were supposed to use 30w , does that not matter with the back half gone?
Yea i think the 30wt was because of the chain end....
I run 80-90 in mine.


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Old 05-25-2012, 05:14 AM   #14 (permalink)
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Originally Posted by EricsGreen98Tj View Post
Well since you cant run with the chatter than it evidently is a problem with the doubler mounting location. Either mod your existing crossmember or build a new on..

Im curious as to why you took the whole thing apart, put it back together, and stuck it back io the same off center crossmember???
My thoughts, exactly, but I just couldn't bring myself to say it. This poor fucker has enough problems without me telling him what he already knows. He fucked up.

My biggest question, also unasked for the same reason, is why post up a thread with a question you already know the answer to? Was it only to hi-light his fab(or lack thereof) skills later with pics?
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Old 07-30-2012, 11:26 AM   #15 (permalink)
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I have the NWF 203/205 doubler setup (mated) and I'm getting the same noise I think? I get noise in gear when I'm coasting and also when it occurs and i shift into neutral rolling. Puzzled.
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Old 07-30-2012, 05:30 PM   #16 (permalink)
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im running 203/205 doubler from jeds mated to a 435 and mine does it when the 203 is engaged, the faster i spin it the louder it gets.
wait.. I may be crazy or just plain wrong since its been a while since ive spent much time in my truck but I dont think my truck will even move with the 203 in nuetral?
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Old 07-30-2012, 10:01 PM   #17 (permalink)
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does it make it less if you hold the shift handle of the 203?

If so, maybe the shifter is loose... sounds stupid, but it happened to me.

That and your angles being retarded.
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Old 07-31-2012, 02:13 AM   #18 (permalink)
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lol
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Old 07-31-2012, 06:48 AM   #19 (permalink)
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im running 203/205 doubler from jeds mated to a 435 and mine does it when the 203 is engaged, the faster i spin it the louder it gets.
FWIW, I have the Jed's doubler too only behind a T-18, and mine growls/chatters pretty good when the 203 is in low... 80-90w in all my cases too.
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Old 07-31-2012, 03:08 PM   #20 (permalink)
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my buddy mr technical, worries about every rattle and noise there is freaks everytime he gets in my truck cause he swears the transfer case is gonna fly apart lol
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Old 10-11-2013, 11:29 AM   #21 (permalink)
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Can one of you running the divorced 203/205 doubler setup tell me how long it is?

Center of 203 Input yoke to center of 205 output yoke.

Please and thank you in advance.
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Old 10-11-2013, 10:02 PM   #22 (permalink)
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Can one of you running the divorced 203/205 doubler setup tell me how long it is?

Center of 203 Input yoke to center of 205 output yoke.

Please and thank you in advance.
I will be at my shop Saturday morning and check it out for you. The main issue I had length wise was with the intermediate shaft. Hard to get that thing short.
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Old 10-12-2013, 07:11 AM   #23 (permalink)
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I will be at my shop Saturday morning and check it out for you. The main issue I had length wise was with the intermediate shaft. Hard to get that thing short.
Please do, that info would be awesome.
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Old 10-13-2013, 01:55 PM   #24 (permalink)
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FordX4-Offroad you have a PM.
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Old 10-13-2013, 06:39 PM   #25 (permalink)
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I will be at my shop Saturday morning and check it out for you. The main issue I had length wise was with the intermediate shaft. Hard to get that thing short.
I see up there they are using a normal driveshaft for that, could probably use the center "yoke" of a double cardan joint to get it really short.
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