A few 208 rebuilding ?s

[randy88k5]

I got this 208 transfer case from the junkyard for rebuilding. I know its been worked in before (antisieze, blue RTV), but I do not know what was done to it.

The haynes manual says to discard the front output shaft yoke nut after it is removed. Is this correct? Can it be used again without worry? Where would I get a new one if needed?

Also, 2 of the syncronizer mode fork pads (blue and white) are worn almost to non-existance, but I cant see where the play would be to have caused the abnormal wear. I got new pads in the rebuild kit. Should I worry about the cause? Is that normal wear? What would I look for and where? Can I buy a new fork?

Thanks

-Randy

 

[scrappy88]

The fork pads just wear out, it's normal. Put the new ones on and don't worry about it. It's been a while since I rebuilt mine but I think the front output shaft yoke nut is one of those taper locknuts that you're supposed to replace with a new one whenever you take it off, but no one ever does. I reused mine without a problem. I threw some red locktite on mine as well.

 

[randy88k5]

THANKS

 

[Kiwi John]

Where did you get your 208 Repair Kit from?
What parts were in it??
How much did it cost???

Grateful for any info. Thanx.

 

[scrappy88]

I got mine from Transmission Exchange co. www.txchange.com and it came with all the ball bearings, seals, shift fork pads but it didn't come with a new output bushing. I don't remember what it cost me though. It was a pretty complete kit, I was happy with it.

 

[randy88k5]

I got mine form Rockland Standard Gear.

http://www.rsgear.com/

 

[Kiwi John]

Thanks Scrappy. Thanks Randy. I'm looking them up and they're most helpful.

 

[randy88k5]

Well, another snag...

I read a thread about getting the front shaft bearing out of the housing, and now I cant find it ...ive searched... musst have overlooked it several times.

I cant seem to get the bearing out of the blind hole. This is the one on the rear facing cover. Ive been prying with a BFS, but it does not even budge.

Anyone else have luck getting this one out without damaging anything?

 

[randy88k5]

OK, its out.

For anyone else with a problem getting this one out, heres how I did it:

-Pry the guts of the bearing out so your left with the empty shell.
-Use a 2-jaw attachment for a slide hammer on the ring.

I wedged some wood in beween the jaws so the jaws didnt move when in place. I stood on top of the cover while hammering. It came out in about 5 whacks.