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208 popping out of 4hi

Taylormade

Taylormade

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Ok since I cleared up how to re-seat my tires on the trail.....which is expected to happen again....gotta love the 16.5's! I have another ongoing issue,this time with my TC. It seems like every time I have it in 4hi and give the truck a generous amount of right foot, the TC will pop into 2wd. I have had this problem since I bought "gumby" in 2004. Anyone else have or have had this problem? Anything more than a quick fix and I will opt to keep using 4lo!:whistle:
 
It is either the shifter out of adjustment or the pads on the shift fork are worn/broken and need to be replaced.
 
208's usually pop out oh 4low but in your case id check the engine/tranny mounts first then body mounts maybe you ride is flexing enough to make the transfer case lever move.. if everything is ok the your 208 is fu....
 
How can I adjust the shifter? And now that it's brought up, it has jumped out of 4lo before....once. Didnt think anything of it. But I dont even use 4hi anymore its so unreliable in the sense that it pops out so much.
 
Taylormade said:
Manual hubs-stockers
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Actually, since the truck has a 208 (assuming that's what was originally in the truck) you would have automatic hubs UNLESS someone has swapped them out for manual locking hubs (most people ditch the auto hubs as they are trouble).
 
4X4HIGH said:
Actually, since the truck has a 208 (assuming that's what was originally in the truck) you would have automatic hubs UNLESS someone has swapped them out for manual locking hubs (most people ditch the auto hubs as they are trouble).
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I haven't switched out my auto hubs yet. :doah: It's been on my to do list. What are the main problems that people run into with auto hubs? What I meant to say is - Where is the weak point with auto hubs? Or is it just a poor design?

My 208 popped out of 4hi only once. I've never been able to replicate the problem since.:dunno: Must have been flex I guess.
 
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sounds internal, since it's happening a lot. If it was flex, I don't think it would happen as much and certainly not in both 4lo/ 4hi
 
Whoa....I was not aware that automatic hubs were factory with the 208. Good to know I reckon. So my problem is internal? Shift forks/pads? How hard are these to replace? Should I rebuild the unit while I have it out or fix as needed?
 
Problem is definitely internal. Mine got so bad it would pop out of 2wd into N or just grind between gears, just while driving down the street.

I pulled it and brought it to a trans shop and they rebuilt it for me. Now it works like new.
 
I don't remember now, but it was more than I wanted to spend, like 600 bucks. Didn't have too much choice though as I had just sold my 2500HD the week before and the K5 was my only vehicle. But the shop knew what they were doing and had worked on NP208s since the 80s. Told me what went wrong inside before even looking at it, knew what it was when I described what happened. Now the thing works freakin sweet.
 
Hmmmm 600 is more than I would like to spend on it right now. I would have to break it before I spent that on it. Thanks for the ballpark price though, its good to know what to expect!
 
There was a thread on here very recently about a 208 locking up from breakage, I believe that he wasnt able to move the truck at all. I wouldnt want to be in that situation...
 
I had a similar issue with mine popping out as well. I adjusted the linkage and replaced the TC cross member mount. Solved my issues.
 
bot0611 said:
WOW 600...might as well find a good one fast then.
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I had swapped in a "good" used one a year ago. It lasted a year. I don't want to be swapping out t-cases once a year, especially on a daily driver. I need this thing to work properly every day without question. And this winter has proved to be a tough one, so 4x4 is a must have when you need to get to work to drive the plow truck and clear the lot.
 
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