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Tom Woods 208 SYE install

Mastiff

Mastiff

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I bought a kit to SYE my 208. Started today by getting the 208 out of the truck. I've never had it out and didn't know what to expect. It wasn't too bad really, but I didn't trust myself to catch it, so I built a contraption to jack it down.

Here's the starting point:

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Steps for removal:

- Remove front/rear driveshafts
- Remove speedo cable
- Remove 4WD indicator connector
- Remove breather hose
- Remove shift linkage
- Drain fluid
- I partially remove the parking brake cable to get it out of the way
- Remove 6 bolts connecting t-case to adapter
- Remove two bolts attaching t-case to brace

I put my trans jack up there to hold things in place before removing the bolts all the way. Once they are removed, the t-case will rotate down and fluid will pour out of the adapter. It will not fall since it is hanging on the trans output shaft.

Here's how I modified my trans jack:

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Just some scrap lumber to cradle the case when it comes down. When I pulled it back, it tipped over to the side and layed on the side of the cradle. The case isn't especially heavy, but if it is dropped it could crack.

Here it is removed:

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In my case I have a TH400, but the t-case still has 27 splines. The trans swap happened a long time ago and I wasn't sure how it was done, but it looks like the TH400 was modified to 27 spline.

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Next is to tear into the case. Any suggestions how best to clean the case first? Would it be bad to pressure wash it?
 
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if your tearing it apart. they make a heavy duty chain for the 241 and I think the 208. might want to look into that since its gonna be apart.
 
Blazooki said:
if your tearing it apart. they make a heavy duty chain for the 241 and I think the 208. might want to look into that since its gonna be apart.
Click to expand...

I've had no trouble with the case, so I'm going to do the minimal I need to, but I think the chain does need to come off to replace the main shaft, right?
 
Anyone know where to get a heavy duty chain for 208? I've read that a 241 chain is the same, but have not been able to confirm.
 
Mastiff said:
Anyone know where to get a heavy duty chain for 208? I've read that a 241 chain is the same, but have not been able to confirm.
Click to expand...

Sorry dude, I only replaced mine with a factory unit. IIRC my 241 got a factory unit also.
 
ww.onlinetransmissionparts.com/servlet/the-Transfer-Case-Parts-cln-Chains/Categories

looks like the heavy duty chain only fits the dodge.....
 
Blazooki said:
ww.onlinetransmissionparts.com/servlet/the-Transfer-Case-Parts-cln-Chains/Categories

looks like the heavy duty chain only fits the dodge.....
Click to expand...

That's what I was starting to think. It's wider, but you'd need the other parts to go with it.
 
Did a little more work on this. Not hard so far: Removed the rear "cone" and the back of the case. Everything came off pretty easily. I found that a milk crate is the right size to hold the case.

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Here's the old tail and the new parts. You can tell there's not much to it, they just chopped stuff down and machined the cut down tail housing for a bearing.

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Next comes a few snap rings and in theory I should be able to lift the two chain sprockets up and out. Anyone know how the speedo gear is removed? I tapped it around in a circle but it didn't want to come out from the outside. I haven't tried tapping from inside yet.
 
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Made some more progress. I was all greasy and had someone helping, so I only have the "after" picture, with the new mainshaft installed:

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It's not bad, as long as you know about the needle bearings... :whistle:

There are snap rings holding each sprocket on. Once those are removed, the two sprockets and chain can be lifted out together. The trick is that on the mainshaft side, there are two rows of loose needle bearings under the sprocket. If you ar very careful, maybe you can get it apart without spilling them. I was oblivious, and a dozen or so fell out or into the case.

Once the sprocket is off, the mainshaft can be lifted up along with the synchro and shift fork until it can be pulled sideways away from the fork. Then there's another snap ring on the back side to remove so the synchro stuff can be removed.

After that, transfer the synchro stuff to the new shaft. Attach the needle bearings to the new shaft, insert it and carefully put the sprockets back down. It's touchy to do this without messing up the needle bearings, but that's it.
 
All put together. I used "the right stuff" instead of gaskets, hopefully this will be a wise choice. I doubt it will leak, but it's possible I could end up with an RTV snake inside the case since the parts fit together so well.

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Up on the jack ready to go in. I'm going to get a second person if I can so I can stay under control with the RTV in place and not make a mess, plus get it all bolted up within the 5 minutes recommended.

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While I was at it I got one of these U-joint gaurds from DIY4x. Very stout design. I did find that the provided bolts were bottoming out before tightening up. Maybe just rust and crud in the threads way down in there. I found some washers and it seemed to do the trick.

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