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And The Transfer Case Went BANG!

uglytruk

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IN A JUNKYARD, UNDER A TRUCK*N E Rust Belt
I just started using my '84 K5 Blazer 6.2, and was plowing a bit of snow in the country last nite. I had to go up the dry road 1 mile, so I put the 208 TC in 2 high, backed up a bit, and proceeded on my way. I suspect the TC was still in 4 high bcauase the Blazer was pulling a bit to the right. I kinda' ignored it bcause I was just going a few hundred more yards.

A few seconds later I hear and felt a huge BANG!. Yikes, I pulled right over expecting to find the front driveshaft or something dragging!. Nothing. All seemed well until I put it in 4 low to pull off the shoulder were I pulled over. It immediately popped outta' 4 low, so I figured I had maybe broken a shifter fork, something I had heard was a weak part.

Well, we just got 6 inches of snow this AM, and I just finished 4 hours of plowing in 4 low and hi, and it never popped out or acted up. What happened?

BTW, I had just checked the oil level in the TC, and it was fine. 1st time EVER. They're ALWAYS 1 or 2 quarts low! And this K5 is the epitome of neglect.

One other issue.

The 3 foot long strut is missing from the engine block to TC. My last Sub was also missing it, but the bolt into the block was broken. Is there a better block-mount bracket, or should I fab one that attaches to 2 bolts? Two HUGe bolts on the TC, on baby bolt to the block...

Oh yeah... Last thing... 30 years ago my friend had a '77 Sub 305 HO (Z28), TH350, NP203. We installed a small cast iron corner bracket between the tranny mount and TC. I remember helping him install it, as we had to grind some of the iron due to interference, and his output area of TH350 was cracked and seeping. The bracket Seemed like a good idea...

CIMG9981.JPG

CIMG9983.JPG
 
the strut to the block is a good idea it helps with case flex and to keep from cracking your tranny adapter as well.

My guess would be the bang might have come from a loose chain or the t-case being bound up and releasing when it decided to go back into 2wd.
 
so I put the 208 TC in 2 high, backed up a bit, and proceeded on my way.
Sound like you have automatic hubs? Maybe the right hub stayed locked causing the truck to pull to the right. I wouldn't be surprised if the bang was the other one engaging again, but it may have just been the TC popping out of gear.
 
Sound like you have automatic hubs? Maybe the right hub stayed locked causing the truck to pull to the right. I wouldn't be surprised if the bang was the other one engaging again, but it may have just been the TC popping out of gear.
x2.
 
I just swappped to manual hubs.

I always back up after switching outta' 4wd, but I guess it didn't disengage. What breaks in the 208? Do the shifter forks just wear? Anybody got a pix of the guts of a 208?
 
with manual hubs there is no need to back up. did you pack the hubs full of grease?
 
i thought maybe you filled them full of grease. they are not to have any grease in them.
 
I always had issues with my 241 in the Burb. Went into 4hi fine but always had issues going back to 2hi. TC would bind and pop no matter what I did. When I replaced it with the 465/205, I separated the trans and TC. I played around with the shifter and found that even out of the truck it still had issues. So I'm thinkin the shifter fork was f---ed up. Didnt care to fix it as I had a new drivetrain.
 
You should adjust the linkage and make sure everything looks OK with it. If you still have problems, it could be the shift forks/pads. They do wear out, especially if you have a lot of miles with a misadjusted linkage.

You can see the diagrams and replacement parts here: http://www.drivetrain.com/208transfercasesillust.htm


208_p2.jpg


208_p1.jpg
 
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