NP208 popping out of gear

[Cntymnty77]

I’ve had this K5 for a little over a year now and I noticed shortly after I got it that the transfer case popped out of gear under load. I got under the truck and noticed the old rubber trans mounts were smoked. Fast forward to today, I changed out the old mounts with new Energy Suspension mounts, got it buttoned back up and went for a drive. I went over to a piece of county land that was flat but also has a few small hills and put it into 4Hi while on the pavement and then as I drove onto the muddy ground and hit the resistance it popped out. I put it into neutral, back into 4Hi and held the shifter in place. Made a few passes and never had a problem, as long as I held on to the shifter.

There is no body lift or any suspension lift on this thing. What else would cause this issue?

New and old.


Before they were changed out.

 

[Vombrown]

Before you do anything else, check your linkage and shifter. I've seen plenty that the Z plate on the floor had moved and did not let the transfer case fully shift into gear. Get under the truck and disconnect the linkage and shift it into gear with your hand. You'll feel it click into gear. Now connect the linkage with the shifter in the correct location. It has an adjustment there if it doesn't line up. Check all the positions this way. If it all lines up and is holding and locking into gear then you need to take the transfer case out and have a look see.

 

[Chevy305]

If your transmission mounts were that bad then you need to change your motor mounts too.

 

[sweetk30]

208 cases can get worn bad inside and pop out of gear . years ago one of mine did this and had to be rebuilt or replaced .

fyi newer 241 from mid 85's to 89 will be direct swap and better case .

 

[Cntymnty77]

Before you do anything else, check your linkage and shifter. I've seen plenty that the Z plate on the floor had moved and did not let the transfer case fully shift into gear. Get under the truck and disconnect the linkage and shift it into gear with your hand. You'll feel it click into gear. Now connect the linkage with the shifter in the correct location. It has an adjustment there if it doesn't line up. Check all the positions this way. If it all lines up and is holding and locking into gear then you need to take the transfer case out and have a look see.

I’ll have to check all of that! Thanks!

If your transmission mounts were that bad then you need to change your motor mounts too.

those are still on the to do list..

208 cases can get worn bad inside and pop out of gear . years ago one of mine did this and had to be rebuilt or replaced .

fyi newer 241 from mid 85's to 89 will be direct swap and better case .

I have a feeling, the way this build has gone so far, this is probably the case..

 

[GWeakland620]

Another vote for checking shift linkage. I’ve had 2 t-cases I thought were bad, but just needed the linkage adjusted.

 

[Blue85]

If it does end up needing shift pads (and possibly forks), rebuilding a NP208 is an afternoon project (as long as you don't lose any roller bearings!). But I agree, to check the linkage out well before fearing it needs more.

 

[Truckman4life]

A little late to the party but I vote shift linkage also. My 208 would pop out of 4LO when under any load. I barely adjusted my linkage a few turns and problem fixed.

 

[GWeakland620]

A little late to the party but I vote shift linkage also. My 208 would pop out of 4LO when under any load. I barely adjusted my linkage a few turns and problem fixed.

Same

 

[Cntymnty77]

Thanks for the input! Looks like I need to go out and try that linkage and hope that’s all it is.

 

[Truckman4life]

You can also eliminate the internals by disconnecting your linkage popping the t case into gear and driving it to see if it still pops out with no linkage.

 

[sweetk30]

my 208 that died when I pulled the drain plug it had guts falling out of it .

 

[Cntymnty77]

my 208 that died when I pulled the drain plug it had guts falling out of it .

I guess that’s one way to figure it out!

You can also eliminate the internals by disconnecting your linkage popping the t case into gear and driving it to see if it still pops out with no linkage.

the only thing that would scare me about that is the gears grinding. When it pops out, it grinds pretty badly.