208 popping out of 4hi

[samsterman99]

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.

Same thing happened to me yesterday, the problem was manifesting until I couldnt keep it in 2wd for more than 100feet on the road, had to run in 4 low all the way to a shop. they had a rebuilt 208 in stock and are swapping it in as I type this. I tried all the adjustments in the world and new mounts, the problem WILL get worse, and eventually the pads will come off the forks totally, and you will be without Hi gears.

 

[Muddytazz]

Its the pads on the shifter fork that wear out. I just went through this on my K5's 208. Same thing, would pop out of 4hi, hell I actually had to hold him IN 4hi at the end cause it would not stay there if you let go of the shifter.

 

[Blue85]

First things first. Go adjust the linkage per the manual. Then move on.


You probably just need new shift forks. Since you are popping out of 4HI, that would be the mode fork, but I would do both of them while in there unless the range fork and pads look brand new. You can get the two forks and 6 pads here for about $100: http://www.drivetrain.com/parts_catalog/transfer_case_replacements_and_parts/np208.html The seals and O-ring kit is $24.

If you can live without the vehicle for a while, do the tear down first and inspect all of the bearings and the chain tension. Then order parts.

 

[shadow6000]

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.

Too bad you're not closer to me. I've got a NOS 208 sitting around that I need to get rid of.

 

[Taylormade]

I dont drive the blazer as a dd, I would like to fix it before it gets worse. I like the sound of ~$125 to fix this problem. Thanks

 

[TheBeast_88K5]

It is either the shifter out of adjustment or the pads on the shift fork are worn/broken and need to be replaced.

I had this EXACT same issue on my '88.
I had to have the Tcase rebuilt, because the shift fork pad had disintegrated.

Then, it still happened....
I had to adjust my shift-linkage about 2" toward the tcase.

Now it clicks-and-sticks....

(I have a 6" lift on my '88.....)

 

[84 k5 blazer]

same problem, kept coming out of 4hi. I adjusted the linkage and it fixed the problem. Took maybe 5 minutes and cost nothing.

 

[digs]

I had this EXACT same issue on my '88.
I had to have the Tcase rebuilt, because the shift fork pad had disintegrated.

Then, it still happened....
I had to adjust my shift-linkage about 2" toward the tcase.

Now it clicks-and-sticks....

(I have a 6" lift on my '88.....)

Beast. Define 2" towards the Tcase. Do you mean shortening the linkage or lengthening it? I have a 6" lift on my 91 and have had it pop out of 4hi and 4lo.

 

[Blue85]

Here you go:

 

[TheBeast_88K5]

In the diagram, that blue85 posted.....

-The simple explanation is to place shifter in 4Hi.
-Then, get under the truck, and loosen nut "B", first.
-Then, loosen nut "A", and keep crankin' it toward the t-case. (mine took 2")

-move the "lever assembly" (square part), flush with nut "A".
-Tighten nut "B", to firmly hold 'lever assembly' in place.

- take the truck out and test it.

It took me two adjustments to get it right...

My shifter now *clicks* into 4hi, and 4lo.
You can tell the difference after proper adjustment.

Fwiw... the directions, especially step 10 (wtf?), didn't make any sense to me.....

Maybe 4x4 high, or someone, could shed some light on the gauge tool, as well....
I didn't use one, but I don't use gaskets on my diffs either....

 

[Blue85]

I've never heard of anybody using that shim tool. Just put a screwdriver in there or cut a thick washer. Having the adjustment right not only prevents the case from "popping out" it also maximizes the life of your shift pads. The fork can "float" out of the way if the linkage allows it. But if the shifter is against a stop it forces constant rubbing on the side of the pads.

 

[Blue85]

I think steps 9 and 10 are just saying to put the case in 4HI and also put the floor shifter in 4HI.

 

[pblaze725]

I had the same problem w/ my NP 208 except mine would pop out of 4LOW. I adjusted the linkage & it helped a little. I eventually took it to get rebuilt. I got ripped off & paid more to rebuild T case then I paid for the entire rig. I'm so ashamed!
It works great now & is still covered under warranty. It sounds like its the shifting forks, it's a common problem. If you have the skills to rebuild it yourself go for it. Remember if it fails ,you have no one that you can bring it back to.

 

[bot0611]

I had the same problem w/ my NP 208 except mine would pop out of 4LOW. I adjusted the linkage & it helped a little. I eventually took it to get rebuilt. I got ripped off & paid more to rebuild T case then I paid for the entire rig. I'm so ashamed!
It works great now & is still covered under warranty. It sounds like its the shifting forks, it's a common problem. If you have the skills to rebuild it yourself go for it. Remember if it fails ,you have no one that you can bring it back to.

Hey man how much did it run you to get it rebuild? and where did yo go to i need to get mine checked out.

 

[pblaze725]

I went to SCAAMCO. I paid $1600 in parts & labor.
A few weeks ago a buddy of mine had a free NP208 he was going to give me along with a couple driveshafts & a x member that was notched where the front driveshaft contacted it. He had it stored at his shop for a year with no problems, as soon as he pulled the parts out, somebody stole them before he had a chance to give them to me.

 

[bot0611]

Fuc.....$1600 WTF did they cover it in gold or something.. screw that ill get one in better shape from pick and pull and ill try to do mine myself, thanks for the info ill avoid them in the future.

 

[samsterman99]

Fuc.....$1600 WTF did they cover it in gold or something.. screw that ill get one in better shape from pick and pull and ill try to do mine myself, thanks for the info ill avoid them in the future.

I paid 595 for a new totally rebuild 208 up here at TransAction, they had me in and out in less than a day because I needed it for that weekend. Although I was hard pressed to dump 600$ into a new case that just needed 50$ forks, the TCase shifts to smooth and is butter going into all ranges.

 

[pblaze725]

Fuc.....$1600 WTF did they cover it in gold or something.. screw that ill get one in better shape from pick and pull and ill try to do mine myself, thanks for the info ill avoid them in the future.

It still hurts. I could have saved some money by pulling it out myself but I let them do it. I also got the 1 year warranty,I figured I would beat the hell out of it and take it back if I had any problems. I was also in a rush to get it fixed before TDS 2010.
Actually they covered it bedazzle gems.