i looked into it yesterday a 205 runs about 200 bucks up here plus you need the driveshafts because they are shorter on a 205
i am going with the 60 dollar milemarker conversion kit but have never opened up a transfer case should i be afraid
Don't open the case unless you ase sure about it. Not that it's hard but if never before it may look confusing.
$200 for a 205, I guess price vary's in location. Are you sure about shaft length needing a change? I am going to ask someone about that to be sure as I thought it was a strait forward swap.
The 203 is a really handy transfer case for plowing. I love it for quick touchups on spotty traction areas. No binding on hard dry surfaces.
As for difficulty, never personally did one (watched though!). Problem is, its probably in need of an overhaul and a chain, and thats where things get hairy real quick.
If your OK with just doing the conversion, then you'll be OK. If you question its condition and may need an overhaul, you may want to consider sending it out to a 4x4 shop and have them overhaul it and install the kit.
The 205 is a bulletproof case. $200 is cheap!
Don't know about shaft length either, though a driveshaft modification isn't that much money, and you'll probably need a new slip joint anyway!
scottyd, I have personally done one of these conversions. The hardest part of the whole job is adding the fluid. No lie it is that easy. If you don't have air available, you will need a good breaker bar and a big pipe wrench to get the nut off and back on the yoke. I'm assuming you are also adding locking hubs too. That is also not a big deal. I had my Chevy up and running within an hour after doing both the t-case and the hubs. It was also my first time doing either of those tasks.