Transfer Case Issue

[daleearnhardt01]

Blazer I am buying from a fellow member and friend here has an issue with the t-case. We have torn the drivetrain out so I can swap a motor that I have into the truck. The truck was used as a sand drag truck so it was always run in 4wd and rarely on the street so I have not witnessed this problem as the only time I ride in it, it is in 4wd. He says the case will pop out of 2hi and try to go into 4wd when hitting the brakes. It is a 208 case. Before we put it all back together Id rather correct this issue so I dont have to drop the case again. Any ideas on what the problem is?

 

[resurrected_jimmy]

search this issue on here, it comes up every few months, it has to do with the shift fork and the teflon pads wearing out, I think pauly383 has rebuilt a few with this type of problem

 

[odin]

Thats right, the range forks wear out causing it to jump out of gear under load.
Very easy to replace.
Search and you should find a writeup on it.

 

[daleearnhardt01]

Cool, thanks for the info guys. I kinda figured it was something to do with the forks...

 

[daleearnhardt01]

Where can I get the pads at?

 

[daleearnhardt01]

Well took the case apart today and found that the range fork (I think thats the one, whichever one is closest to the planetary set), was totally chewed up. I am going to pull apart another case I have and hopefully rob it out of that case so I dont have to buy a new fork.

Is there anything else I should be concerned about with that fork being so chewed up? Everything else in the case looks fine as far as I can tell.

Anybody got a good exploded diagram for this thing?

 

[resurrected_jimmy]

here ya go

 

[daleearnhardt01]

Well I took apart the spare 208 I had lying around and have found some interesting things. The extra case had some parts that the original one does not have. Apparently the original case is missing the syncro ring/gear shown here.

The spare case also had 2 snap rings, shown by arrow, and 3 keepers, circled, that werent in my original case.

What gives here? Clearly I think the syncro will make its way into my case but what about those snap rings and keepers?

 

[k30bb468]

Diagram of NP208 here:
http://www.drivetrain.com/208transfercasesillust.htm

 

[daleearnhardt01]

Yeah every diagram I have seen shows those parts, I have no idea how that case was working without those parts. Luckly I had this extra case!

 

[resurrected_jimmy]

oops I posted the wrong T-case, I put the 203 up by accident

 

[daleearnhardt01]

oops I posted the wrong T-case, I put the 203 up by accident

Yeah its all good, transfer case is back together and seems to work okay, we'll find out for sure when its put in the truck at a later date...