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NP208 Fluid Capacity, Bone to pick...

I always thought I updates this post way back when. The fill hole will allow you to overfill it. However a lot of my issue was actually due to clocking the case allowing the capacity before it came from the plug to increase.

Proper capacity is in fact 5 pints aka 2.5qts.
 
Good call. I have all my CUCV manuals electronically. Pretty clearly says to fill to the bottom of the plug, and the capacity of 5 quarts is consistent with that.

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I wonder if they changed it with the transmisions. I looked at my book, it says 5 pints. 700r4 is in front of mine.
 
Dunno. Oddly enough, I've seen it both ways. Six pints in a GM training manual and then fill to the plug in the ARMY manual. In the end, I used the ARMY reference. As a member of the Army, I know we have very low tolerance for oil leaks on equipment and if the manual was wrong there would have been a change. I'll find it somewhere if anyone needs it. It's the manual for rebuilding the case. I was actually still able to find it in the archives of the military maintenance websites we use, so I know it included any revisions.
 
The Dodge 208 has the fill plug a lot lower. Other than OEM preference, I can only think of two reasons why:
1) The bushing in the slip yoke is better with more fluid
2) The speedo output in the Chevy would be above Dodge fill line (seems like it would still get plenty of oil.
I don't think they were clocked any differently in the vehicles. Both have that little oil pump in the back.

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My case has all 3 (could make somebody scratch their head). I fill to just under the upper one and honestly I haven't seen any signs of leaks. I think a slip yoke almost has to leak a little as the yoke travels in and out of the seal.

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It's on the left instead of the right. You can sort of see it in my 1st picture. The gear holder is smaller than the Chevy one - they are like Jeep speedo gears.
 
Blue85 said:
It's on the left instead of the right. You can sort of see it in my 1st picture. The gear holder is smaller than the Chevy one - they are like Jeep speedo gears.
Click to expand...

That thing is costing me an inch or two on total length! :D
 
Length of the case, driveshaft or speedo cable?
 
So you think the TW solution is 1-2" longer than the Dodge? That still makes the rear driveshaft 4-5" longer than with stock 208.
 
Blue85 said:
So you think the TW solution is 1-2" longer than the Dodge? That still makes the rear driveshaft 4-5" longer than with stock 208.
Click to expand...

Just eyeballing the pic... I'm not really complaining, the TW solution should do fine and did indeed shorten up the t-case noticeably. And my speedo plugs right back in.

My install is in the build threads area FYI.
 
Lots of folks stating military manual ...so this is the latest, active lube order from the US Army.

Military lube order LO 9-2320-289-12 June 16 1986 Card 9 of 9 item 14.

14. TRANSFER CASE (205 AND 208) .....Fluid should be approximately 4 inch (6.4mm) below the edge of the
filler hole.

I have never seen this recommendation before. FYI. http://www.radionerds.com/images/2/29/LO_9-2320-289-12.pdf
 
richardnm said:
Lots of folks stating military manual ...so this is the latest, active lube order from the US Army.

Military lube order LO 9-2320-289-12 June 16 1986 Card 9 of 9 item 14.

14. TRANSFER CASE (205 AND 208) .....Fluid should be approximately 4 inch (6.4mm) below the edge of the
filler hole.

I have never seen this recommendation before. FYI. http://www.radionerds.com/images/2/29/LO_9-2320-289-12.pdf
Click to expand...

Must be a typo, as 4 inches is not even close to 6.4mm, more like 100mm.
 
richardnm said:
Lots of folks stating military manual ...so this is the latest, active lube order from the US Army.

Military lube order LO 9-2320-289-12 June 16 1986 Card 9 of 9 item 14.

14. TRANSFER CASE (205 AND 208) .....Fluid should be approximately 4 inch (6.4mm) below the edge of the
filler hole.

I have never seen this recommendation before. FYI. http://www.radionerds.com/images/2/29/LO_9-2320-289-12.pdf
Click to expand...
6.4mm =1/4" not 4"
It's a typo
 
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