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possible rebuild on my trans/tcase?

Chevy305

Chevy305

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So I just put a clutch on order through Summit, and since I am going to be dropping the trans and t-case I think I want to rebuild them. I have never attempted anything more complicated than a diff, so it will be a learning experience for me.

I have the sm465/208 combo and I am looking to get rid of a rattlely/chattery noise that happens on the highway. And I want to tighten up my shifter some. I have read about the spot weld that can break on the end of the shifter.

I don't want to comepletely tear apart my trans, but while I have it out, is there anything else I should do other than the spot weld on the shifter?

On the t-case the only problem I have is the chattery sound which I believe could either be the coupler or the tail shaft. But I won't know until I take it apart. Where can I get a rebuild kit for it?

Also any advise on this would be wicked awsome! :D
 
I'm not to sure on the tranni. but the Np208 is easy as pie to do. I did my first one with this diagram of the case:
http://www.myk5.net/modules.php?name=Content&pa=showpage&pid=6
Granted I was just switching over the guts....But I did take the chance to rip apart the gears.....the only sucky part is all of the small bearings in between the shaft and one of the gears.
I'm guessing any place like this site is a good place to start looking for a kit.
http://www.drivetrain.com/transfercasesparts.html#New Process Model 208
........I have never rebuilt a diff but from what I know I would think that rebuilding the case is easy.
Thanks
Adam

Chevy305 said:
So I just put a clutch on order through Summit, and since I am going to be dropping the trans and t-case I think I want to rebuild them. I have never attempted anything more complicated than a diff, so it will be a learning experience for me.

I have the sm465/208 combo and I am looking to get rid of a rattlely/chattery noise that happens on the highway. And I want to tighten up my shifter some. I have read about the spot weld that can break on the end of the shifter.

I don't want to comepletely tear apart my trans, but while I have it out, is there anything else I should do other than the spot weld on the shifter?

On the t-case the only problem I have is the chattery sound which I believe could either be the coupler or the tail shaft. But I won't know until I take it apart. Where can I get a rebuild kit for it?

Also any advise on this would be wicked awsome! :D
Click to expand...
 
check the syncronizers for 1st, 2nd, & 3rd. from what i know as long as the syncros and the gaskets are good, the gears and shafts should be good. does the sm465 have a bushing that the shifter sits in on the top of the tranny?
 
I didn't bother rebuilding my 465 when it was out. I didn't have any real reason to, it shifted just fine.

200K and its only been out of the truck that one time in 30 years for a clutch replacement, still works like a champ ;)


I have doubts that rebuilding the 208 will fix your driveline chatter/noise, I would bet its more likely driveline vibrations. It could fix it though, bearings that are on their way out usually have the same symptoms.
 
38377k5 said:
I didn't bother rebuilding my 465 when it was out. I didn't have any real reason to, it shifted just fine.

200K and its only been out of the truck that one time in 30 years for a clutch replacement, still works like a champ ;)


I have doubts that rebuilding the 208 will fix your driveline chatter/noise, I would bet its more likely driveline vibrations. It could fix it though, bearings that are on their way out usually have the same symptoms.
Click to expand...

Well both trans/tcase work and opporate perfectly, I'd really just like to get rid of the noise. I do plan on doing gaskets and seals regardless.

I think you may be right, I have heard of people swaping whole drivetrains and still not get rid of the noise. :crazy:

I think what I'll do is split the two when they're out and check the coupler and splines and make sure they aren't worn out. Also I'll take a gander inside the inspection covers of the trans too.
 
A few years ago I rebuilt my NP 205. I was reluctant to just tear into it without some backup info. I ordered a VHS tape ( I said it was a few years ago ) and wached it about 10 times to get familiar with proper dissasembly, inspection, & reassembly. I ordered the tape from J.C.Witney. I have also seen advertisements for them in the back of Hot Rod Mag. They also carry videos ( probably DVD now) for transmissions also. You might want to check several junk yards. The SM 465 was used for many years in both GM trucks and school busses. There is little demand for this transmission after the SM 2500 and 3500 came out. You might be able to get a mid 80's 465 for $50 - 75. Most junk yards tag their parts so they can retrieve the make, model and mileage. Also, I got the transfer case rebuilding kit from 4X Heaven. They are located somewear in upstate New York. They also carried new and slightly worn used parts if needed.
 
like said the 208 is very simple. Only special tool needed is a good set or lock ring pliers. As for the sm465 I think you need a hydraulic press and a good bearing puller and it should be pretty easy.
 
I'm pretty sure there isn't a coupler between the 465 and the 208. It'll be a 32 spline output going directly into the female 32 spline input of the T-case.

If it were me I'd look to swapping in a 241, better low range, better oiling set-up, and you can get a SYE kit for them.

Rene
 
tRustyK5 said:
I'm pretty sure there isn't a coupler between the 465 and the 208. It'll be a 32 spline output going directly into the female 32 spline input of the T-case.

If it were me I'd look to swapping in a 241, better low range, better oiling set-up, and you can get a SYE kit for them.

Rene
Click to expand...

Aren't the 241's stronger anyways?
 
The 241 is rated for more torque, to the tune of 5555 lb/ft according to NVG specs. From what I have heard the main problem with the 208 is people letting them get low on fluid, starving the bearings of lube. The 241 has it's own oil pump which keeps the thing lubed even when it is really low on fluid. You basically have to run a 241 nearly dry to hurt it. Still, lots of guys run 208's forever. You just have to make sure the fluid stays topped up.

The only words of wisdom I can offer is to NEVER use grease to hold needle bearings or other parts in place, whether in the trans or t-case. The melting point of grease is too high, so it will stay put and prevent the gear lube/tranny fluid from getting to the parts, and they can end up galling.. Use TransJel instead. Other than that, RTFM and you should be fine :wink1:
 
MaxPF said:
The 241 is rated for more torque, to the tune of 5555 lb/ft according to NVG specs. From what I have heard the main problem with the 208 is people letting them get low on fluid, starving the bearings of lube. The 241 has it's own oil pump which keeps the thing lubed even when it is really low on fluid. You basically have to run a 241 nearly dry to hurt it. Still, lots of guys run 208's forever. You just have to make sure the fluid stays topped up.
Click to expand...

Come to think of it, you do bring up a good point. I did run my case low on fluid for a while. Could that cause the chattery noises I am getting?
 
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