NP208 assembly questions

[Blue85]

My transfer case is NP208, front Chevy, back Dodge that has been working fine since 2004. Lately the oil has been making some glitter, so it's torn apart. Everything looks fine inside except the front wheel drive clutch seems odd to me. I can't find definitive information about the differences in clutch assemblies between GM/Dodge/Ford and various years. It seems like the clutch assembly would go together much better if the slots for the keys were straight up and down on top and bottom, but one side is wide, so the keys flip right out unless the sprocket is on top. Could the little pot metal keys have worn through this and could this be the source of the glitter? I'm leading an overland trip next week and appreciate any insight.

 

[Blue85]

I should add that I have another clutch synchonizer hub in the parts bin and it is straight cut up and down, but it is a different diameter than what has been running (not compatible). I can only assume it's the original Chevy part. The main shaft is Dodge, but I can't find pictures of the Dodge parts.

 

[centexk5]

Mine was cut wide like that. There should be some retaining rings you install to hold them in place. Took a few tries and might have launched one of those keys a time or two.

 

[Blue85]

The part is clearly machined like that and I found another on eBay that looks the same. I brought the parts to the local driveline shop to see if they knew of a different key (wider at one end) or anything else about the setup. There is a bona fide old guy there who was confident it will work fine as-is.

I think that when fully assembled, the keys are secured. The tabs might not even make contact and they are just to ease assembly.

I still don't know where the glitter comes from. I strained the oil with a rag and it doesn't look like a ton of junk. Not much on the magnet, either, but it's only been a couple of weeks. However, the last teardown was partial - I didn't take anything off the main shaft. So it could be old stuff flushed out with clean ATF.

Now if only I can find the 120th needle bearing...

 

[Blue85]

I did find this snap ring was missing.



Here's the junk caught filtering