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    Converted NP203 grinding sound in 2WD

    Final update for me - I installed the mile marker 501 kit, and replaced the differential carrier with one with non-chewed up teeth, and found a replacement spacer at a local trans shop. All back together and filled with 10w30, no more noise, shifts well, and as a bonus the driveline clunk I used...
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    Converted NP203 grinding sound in 2WD

    Yep, that part all looked fine. I’m amazed it ate the spacer behind the Torrington before it ate the Torrington itself.
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    Converted NP203 grinding sound in 2WD

    I missed that in there, thank you. it’s specked out to .31 inches and I just measured mine at .28. Not a huge difference but maybe just enough. There’s a clear groove worn in the back side of the spacer and it’s definitely making contact.
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    Converted NP203 grinding sound in 2WD

    Well, belated update but I finally tore into it - my problem is of a similar nature, but caused by a different part. It looks like I have exactly the same part time kit in mine. My Torrington bearing looked just fine, but the spacer behind it has been eaten quite substantial by the roller needle...
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    Converted NP203 grinding sound in 2WD

    Ahhh, well that looks like a pretty likely culprit. I believe that torrington bearing is what comes with the MM 501 kit, if you look at the spacer on this page: Should be able to get one that way if you have to. When I get into mine I'll let you know if it's the same problem - I bet it is. With...
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    Converted NP203 grinding sound in 2WD

    Sweet well, I’ll definitely get back to it this week and I’ll let you know what I find. Looking forward to your discoveries haha
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    Converted NP203 grinding sound in 2WD

    Yeah that sounds very similar to what I have going on - although it mostly appears under acceleration or load, IE on a hill. It’ll chatter and rattle for a couple second and then go away, and vibrates violently up the transfer case shifter. It’s almost like the metallic buzz you get when grind...
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    Converted NP203 grinding sound in 2WD

    @coolpup32 That sounds exactly like what I’m experiencing. My only update is I pulled the rear driveshaft yesterday, and while the output shaft bearing feels tight in the transfer case, there is a ton of rotational slop. It feels like it’s in that rear differential assembly. I was going to take...
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    Converted NP203 grinding sound in 2WD

    U joints are fine, and yes it’s going into 4wd just fine. No noise in 4 lock, and it works great. I’ve had somebody listen/watch outside the truck and the sound is internal to the transfer case.
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    Converted NP203 grinding sound in 2WD

    It calls for straight 30w non detergent. And yes, I’ve been running it in 4wd regularly so the chain throws oil back into the rear housing.
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    Converted NP203 grinding sound in 2WD

    I have a converted 203 in my 75 K25 - truck is fairly new to me, never been inside the transfer case. It has a piece of threaded pipe so you can overfill it for the part time conversion. The truck had been sitting for a while when I got it so I changed all the fluids, including the transfer...

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