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Old 02-08-2004, 08:24 PM   #1 (permalink)
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ax15/203 info

Hey guys,
I am not sure how many people are interested in this set up, or if anyone even wants to run it. As far as i can tell there isnt much info out there on adapting the np203 reduction box to the ax15. This set up should also work with a NV350 since they are very similar to the ax15.

A little back ground: I have a 91 YJ with a 2.5L and I kep eating ax5's. So i decided to swap in the ax15, that will be in another thread. I had won a DOE Flip kit in a raffle so i planned on running it behind the ax15. I wanted more gearing options for the east coast environment that I wheel in. I thought the only option i had was a KluneV. After brousing through the Vendors Forum i saw that Staz Works had a very affordable 203/205 adapter and he eventually released his 203/300 adapter.

After some research and several PM's with John, we decided that the shifter linkage on the flipped 300 should clear the CHevy 203 box, so i booght the 203 and adpater set up from him. Everything arrived boxed and wrapped nicely with no damage to any of the parts. I received the chevy 203, with the 23 spline dodge input and the 2 piece adapter for the 203/300. His kit also includes the resplined output for the 203 so it mated to the 300.

Now to the specs:
The ax15 has a round 6 bolt pattern and the 203 doesnt. FOr shifter clearance i rotated the 203 90* to the right and marked my holes. Then drilled & tapped and installed the studs. The input you need is frmo a 76-79 dodge np203. Its the same 23 spline as the ax15 output.

The bearing input retainer on the 203 fits perfectly into the ax15 but the face bottoms out with a 1/8" gap between the two cases. The input retainer properly aligns the output/input so you just need to fab a 1/8" shim to fill the gap. The stickout of the input allows for a full 1.42" spline engagement into the tranny.

Since no tranny adapter is used you must fab a retainer clip for the counter shaft in teh reduction box. I just used some 1/8" plate i had. There will also need to be plugs added to the original mounting holes.

Overall its a very simple install. The 203 just needs a few minor mods for it to mate properly with the 203. A vent tube port will also need to be added.

I have not yet installed this into my jeep, depending on the weather i should have everything up and running in the next couple of weeks. All the pics i have are with it mocked up in the floor. I will still need to measure and fab up a shifter and linkage. I also plan to make a new tranny mount that ties to the 203 and ax15, then run a flat skid plate.

I will move my engine forward 3-4" and my rear axle is already moved back 3". There will need to be extensive floor board mods as well.

Dimensions:
ax15/wbellhousing= 24.5
203=5.75"
203/300 adapter=3"
1/8 spacer
d300(short)=10.5"
Grand total=43.75"

Now for the pics: Here is the 203 input in the ax15
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Last edited by YJ4RoX; 03-12-2004 at 08:53 AM.
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Old 02-08-2004, 08:27 PM   #2 (permalink)
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pic of the face of the 203 with the dodge input. The bearing retainer OD is 4.88" and the ID of the ax15 is 4.90".
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Old 02-08-2004, 08:30 PM   #3 (permalink)
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Here is a pic of the 203 drilled for the round 6 pattern and the booty fab 1/8 shim. You can also see the retainer clip for the shaft and the holes that need plugged.
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Old 02-08-2004, 08:35 PM   #4 (permalink)
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Here you can see the reduction box mated to the ax15. Note the blue dot near the shift fork hole. Thats where i am locating the breather tube.
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Old 02-08-2004, 08:37 PM   #5 (permalink)
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All painted and ready for assembly.
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Old 02-08-2004, 08:39 PM   #6 (permalink)
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Here are the STAZ Works parts:
203 plate:
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Old 02-08-2004, 08:41 PM   #7 (permalink)
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The 203-300 adapter
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Old 02-08-2004, 08:43 PM   #8 (permalink)
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Both pieces together. John ships the adapter in two pieces. This will allow e to clock the D300 as flat as possible. Once i get it in the Heep and see how high it can be clocks i will takc it, remove the 300 and fully weld the two pieces.
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Old 02-08-2004, 08:45 PM   #9 (permalink)
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The resplined output for the 203 to engage the 300
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Old 02-08-2004, 08:47 PM   #10 (permalink)
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The first mock up with the 203 fully assembled but before drill/tap and shim.
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Old 02-08-2004, 08:54 PM   #11 (permalink)
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ONe more pic a little closer.

A big thanks to Staz Works for a quality product. The machine work is top notch and everything included in his kit fits together PERFECTLY! The Customer service was great and he shipped in a timely manner.

I will try to update this thread as i get everything installed into the jeep. My goal is to be on the trail by mid march. The drive line should be in shortly.

If anyone needs more pics or has any questions please just ask. LIke i said, i am not sure if anyone is interested in this configuration, but IMO its the beast bang for the buck. I hope this drivetrain will be fairly bullet proof behind my sad little 4 banger.
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Old 02-09-2004, 07:59 AM   #12 (permalink)
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looks sweet man. can't wait to see how it works.
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Old 02-09-2004, 01:52 PM   #13 (permalink)
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Very nice work. I hope your t-case mount support is strong, that is a lot of weight to add to the back of the AX15 aluminum case, I don't mean that as a negative at all, really that is some nice work.
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Old 02-09-2004, 09:27 PM   #14 (permalink)
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nice work

hope it's not too late but DO NOT tap the 203 case for a breather hole. i did and you would be surprised how fast the gears in the 203 pump the oil out of the breather hose and all over the ground. i tried tapping it in two different spots with the same results as the oil in the case pretty much gets tossed around in a big circle.

take the time and tap the 203-300 adapter and run the hose off that.

trust me on that on
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Old 02-09-2004, 11:15 PM   #15 (permalink)
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good luck with the ax-15 man. By the end of this week i will have my 3rd in the jeep in about 10k miles. The original fucked up, and now the reman'd tranny did to.
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Old 02-10-2004, 05:28 AM   #16 (permalink)
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Thanks for the input guys. I plan to make a tranny mount that will basically mount to the 203/300 adapter and have poly bushings on the frame rails. It will tie into the tranny as well.

Thanks for the heads up on the breather issue.

As far as reliability, my junky ax5 lasted 130k, so the ax15 should be more than enough behind the 2.5L. Be sure to use GM or Penzoil Syncromesh in the ax tranny's, if you dont the GL5 will eat away the brass syncros. People have good luck with the redline MT90 in them as well.

I am a little concerned about the weight of the 203/300 behind the aluminum 15, I will jus thave to be extra critical with the mounts.
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Old 03-25-2004, 07:56 PM   #17 (permalink)
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have any pics of the mount? also how much of your floor did you have to beat out? shifters? i am about 2sec from ordering this for my TJ (the adapter)
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Old 03-26-2004, 05:29 AM   #18 (permalink)
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I have a pic of the mount at home i will post it up tonight. I am not sure how different a TJ floorboard is but with my engine 4" forward the 203 fit in the tunnel perfect. i just had to cut out a couple of braces that are spot welded to the floor. For the flipped 300 i had to notch my tunnel opening a little for the twin sticks and had to remove more bracing. I also had to take the BFH to the floor directly under the right side of the driver seat frame. I actually made a new cover for the d300 instead of using the stock one. The stock one has a hump in it to clear the gear, but with the flip and the 1" alum spacer you dont need the hump so i gained 3/4" buy using a flat plate.

If i didnt try to raise everything up so high i wouldnt have had very many floor issues at all. The only thing that hangs below the frame rails are the bolt heads in the plate i have bolted to the tranny. I have a skid plate thats a 1" drop and i have tons of room between the skid and the cases. If you dont run a flat or nearly flat skid you should have less issues.

For the mount i used poly bushings on frame rails and used 1"x2" tube(2" side up) behind the 203 with a 3/16 plate welded to the rect tube that welded to the 203 adapter. i then used 1.5" square tube and a 3/16 plate to tie the rect tube to the ax15. This way the majority of the weight is supported at the back of the 203 and then distributed to the tranny as well. Its not pretty but hopefully it will be effective. It survived my first trip out with plenty of redline attacks.

I was plesantly suprised at how quiet the set up is. I figured with two gear driven cases they would be loud. They shift nice and smooth too. The 203 will shift 98% of the time right off the bat, but most of the time you have to roll a little to shift the 300. No big deal.

I will post the pic of the mount tonight and a pic of my tunnel cover, i still dont have boots on the tranny or 203.
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Old 03-26-2004, 03:43 PM   #19 (permalink)
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Who made you D300 flip kit and how much was it?
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Old 03-27-2004, 06:16 AM   #20 (permalink)
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The flip kit is a Down East Offroad set up. Very nice kit. Its about $600. I won it as a door prize at a trail ride. Otherwise i would have made my own.

Chris here is a pic of the mount i made. The verticle plate is the one that welds to the Staz adapter(the 1/2" plate side). I also ran a couple of bolts through it as well. The flat plate in the front mounts to the 4 holes in the ax15. The boxed in portion kind of frames out the 203. I didnt get a chance to snap a pic of it in the jeep and my skid plate is already on. If ya need any more pics just let me know.
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Old 03-27-2004, 09:02 AM   #21 (permalink)
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Thanks YJ4rox !!

Thanks for posting all this great info YJ!!

Lots of us really appreciate you sharing. I'm gathering up parts now to do a 203/300 (homemade flip) in a TJ.

I'll post when it happens.

Vance (anybody have a Dodge 203 laying around in Nor CA ??)
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Old 03-27-2004, 08:18 PM   #22 (permalink)
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Think this would work w/ an aw4. I've been thinking about it for a while. I was also gonna run a bronco d20.
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Old 03-29-2004, 07:23 PM   #23 (permalink)
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ttt
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Old 03-29-2004, 10:34 PM   #24 (permalink)
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Quote:
Originally posted by YJ4RoX
The flip kit is a Down East Offroad set up. Very nice kit. Its about $600. I won it as a door prize at a trail ride. Otherwise i would have made my own.

Chris here is a pic of the mount i made. The verticle plate is the one that welds to the Staz adapter(the 1/2" plate side). I also ran a couple of bolts through it as well. The flat plate in the front mounts to the 4 holes in the ax15. The boxed in portion kind of frames out the 203. I didnt get a chance to snap a pic of it in the jeep and my skid plate is already on. If ya need any more pics just let me know.
cool, looks good. i am just gathering parts
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Old 03-30-2004, 05:27 AM   #25 (permalink)
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Quote:
Originally posted by csudman
Think this would work w/ an aw4. I've been thinking about it for a while. I was also gonna run a bronco d20.
Assuming the aw4 is 23 spline it should work. It may require some machining to the input bearing retainer on the 203 depending on the webbing in the aw4. I know to mate the 203 to a nv4500 the retainer needs machined. I have never had an aw4 in my hands to inspect one. A d300 can be put behind one so i imagine a 203 can as well.

Good luck chris, I will be heading to Windrock in a few weeks for a real test of the setup. I am bending tube this weekend
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