NP208 tear down?

[k5ryder]

My transfer case is leaking and I've been thinking about pulling it out, cracking the case and re-sealing it. How hard of a job is this? I've always been scared of transfer cases. Does anybody have a write up on this? Also what kinda of fluid goes in it?

 

[big dan]

np208s are easy, don't be scared of them. I opened one for the first time a few weeks ago to fix the shifter linkage and had no problems putting it back together.

If you're just wanting to open it and reseal it you don't even really have to take anything out but the speedo gear and the fluid pump which just slides on the shaft. I would find a bucket, like a 2.5 gal, and set the case input side down into the bucket and start tearing it apart. Lay out the parts as you take them out and put them back in the same order.

Should be able to clean and reseal the case without removing the major internals as long as you're careful and don't knock a bunch of crud down inside it. may be best to pressure wash or steam clean it before you open it up. But if by chance you do tear it apart and cant figure it out someone here can direct you or show pics, I just don't have any myself. Though I do have a case torn apart so I could probably get some if you needed.

Takes atf for the fluid. I use regular hydraulic fluid in mine but that's what I use in the tranny too.

 

[EXJAY]

Wheres the leak at? If its at the output shaft (cone) that mates to the 208 body thats easy just 4 bolts and remove the drive shaft, vent and speedo cable and 4 bolts on the cone and it will pop off. Inspect the speedo gear and pump thingie while your in there. The black plate just slides off the output shaft and you can get a good look at the gears/chain. I just did mine a month ago for the first time and wasnt bad at all. Let the sealant cure overnight before re-filling. Not sure about cracking the entire case