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transfer cases

Discussion in 'The Garage' started by hammermachine, Sep 18, 2006.

  1. hammermachine

    hammermachine 1/2 ton status

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    :bow: How hard is it to remove and install a new NP208. For a layman with limited tools. Has anybody done it before. My current 208 doesn't shift. When you shift the shifter there is no resistance it does not feel like it's shifting into 4hi, 4lo, or anything. Anythoughts.
     
  2. loafer

    loafer 1/2 ton status

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    Crawl under the truck and check the shift linkage. If one of the little cotter pins rusted and broke there is a good chance that it is just disconnected.

     
  3. dontoe

    dontoe 3/4 ton status GMOTM Winner

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    Yeah, check the linkage first.

    On a scale of 1-10 in difficulty,
    1. being changing a light bulb
    10. being auto trans rebuild

    I'd give it a 3.5
     
  4. hammermachine

    hammermachine 1/2 ton status

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    Thanks that's good to know, I'll check the linkage.
     
  5. btolenti

    btolenti 1/2 ton status

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    Its pretty easy.

    1 Drain the case
    2 Remove the driveshafts
    3 Disconnect the shift linkage
    4 Remove the 6 bolts holding the T-case onto the adapter

    I've swapped a 208 to a 241 by myself. It can be done, the cases aren't that heavy, but it would have been nice to have an extra set of hands to lift the transfer case into position.
     
  6. nemesis_pyros

    nemesis_pyros 1/2 ton status

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    You drain the fluid???:confused: :screwy:





    :D
     
  7. MattK

    MattK 1/2 ton status

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    either you drain it or it'll drain itself some. your choice:p: :haha:
     
  8. mrk5

    mrk5 The Sticker Guy Moderator Vendor GMOTM Winner Author

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    You need a 5/8" wrench for the front shaft. probably a 1/2" wrench for the rear driveshaft to pinion yoke. A 9/16" wrench for the bolts that connect the tcase to the adapter. And a 1-3/16 wrench or big cresent for the drain plug. A pair of pliers for the shift linkage cotter pin.

    You'll need RTV or gasket material when you put the new case in.
     
  9. btolenti

    btolenti 1/2 ton status

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    You laugh.....but I learned the hard way. ATF baths are not fun....
     
  10. 4X4HIGH

    4X4HIGH 1 ton status Premium Member GMOTM Winner

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    I don't drain mine when i pull it either, but then again i have a SYE kit on mine. :D
     
  11. btolenti

    btolenti 1/2 ton status

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    Yeah, I was taking my 208 off to install my 241 with SYE at the time.... :D
     

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