Need a lil help to resealing a 208

[Chrisblazzer89]

Okay so my 208 is leaking and I don't want to worry about down time.

So my friend gave me a used 208 off his 88 k5 (Thanks chiefheaphy!!!)

I want to open it up and clean everything and replace the seals and stuff.
Is this a hard task to do or is it a real basic job?

 

[jonathon]

I'd like to know this too.. my cheapo book doesn't cover it and mine has a sllllllllllllloooooooooooow leak that I have the itch to fix!

 

[Chrisblazzer89]

ttt

 

[Hossbaby50]

where is it leaking? That will determine if it can be stopped & how to fix it. If it is leaking from the case halves, tallhousing to case half, or adapter/case seal then just reseal it with some RTV.

If the tailshaft is leaking around the driveshaft slipyoke then you need to do more work. You need to replace the rear seal and probably the bushing inside the tailhousing. Even then it might not stop leaking.

Harley

 

[Chrisblazzer89]

Okay I pulled my 208 apart and on my way to the parts store.

Whats the best way to hold on needle bearings?

What type of RTV should I get??

 

[Hossbaby50]

If you don't dissassemble the mainshaft the needle bearings won't fall out.

I use Ultra Grey RTV on my tcase and is has worked well.

 

[tarussell]

To make sure that you do not have further leaks you need to know why there were leaks in the first place.
Was it just an old seal ?
Was the seal dry rotted & cracked ?
Is there a groove worn in the shaft ?
Is the bushing worn out and causing to much play ?
Are the gaskets seeping ?

Just some thoughts to ponder when finding the reason for a leak.
Keep in mind that the cleaner ( as in dry & no oily resido ) you make two mating surfaces the better.

HTH's Tom

 

[Chrisblazzer89]

I got a replacement 208 that is fine and i am resealing it and cleaning it out.
I got grease to hold on the needle bearings and black rtv

 

[Chrisblazzer89]

Okay I just put my 208 back together but for some reason it wont shift into 4wd (shifting it with a wrench) I'm pretty sure its all together right. When I was putting it together I noticed that the main shaft would want to come out with no problem is this right is it supposed to be held in place by just the tail shaft and chain?

Ill get pics up tomorrow.

 

[Chrisblazzer89]

Ttt

 

[Chrisblazzer89]

Really need help with Question on post #9

 

[Hossbaby50]

If I remember right the mainshaft will slide forward and backward in the case just a tiny bit. As for not shifting into 4x4 try turning the shaft slightly and make sure it is not just off alignment.

If it still wont shift in to 4x4 then you may need to crack the case again and see if the range & mod forks are aligned properly. Did the forks have the little teflon pads on the ends and one in the center?

Harley

 

[Chrisblazzer89]

All the pad were there I still have to open it up again to clean it out better and to paint the case (if its ok to paint the case) and then seal it up. Im gonna take pics when i do and I will post them up so someone can tell me if they see something wrong.

Is it okay to Paint the case? ifso what type of paint should I use?

 

[Hossbaby50]

Ya, it is ok to paint the case. Just paint it with something that ATF might have a harder time eating and make sure the case is completely degreased.

I am almost positive that a little endplay in the case is OK. If it isn't then I might need to pull my case again cause I have some end play in mine and have for years.

Check the shift forks are seated properly is the main thing and that the gears they slide on are moving ok.

Will it go into 4hi and not 4 lo? Or no only 2hi?

4hi is comtrolled by the mode lever and the lowrange is controled by the range lever. Make sure the planetary gears are in OK shape if you open it up again and that the thrust washers and bearings on the input are ok.

If you have excessive endplay on the mainshaft it is probably bad thrust washers on the input gear or the mainshaft right behind the input gear.

Harley