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What would you do? A transfer case dilemma.

Melbatoast

Melbatoast

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Fort Collins, CO
I'm looking for some advice. I have a mostly stock M1008 CUCV with the typical 60/14bolt, 6.2L diesel (still naturally aspirated), TH400, NP208. This elk season my xcase took a dump... it keeps popping out of 2hi and 4hi, making a grinding noise. Only once I come to a complete stop, put it in 4low, move a bit, and put it back into 2hi will it stay engaged for a bit before randomly disengaging within a 1/4 mile. So I had to leave it at an Renegade Offroad in Kremmling, CO again (last elk season I broke my tranny), til I can come up with some dough to fix it. So here is my dilemma, do I take the easy route and get another NP208 from Boyce Equipment for $495 (had to do this in 2008), slap it in there and be done.. or spend roughly $1000 finding, rebuilding and going through the trouble of putting an NP205 in there? I'm currently running 35x12.5's with the detroit locker in the rear, but will be running 37x12.5's locked front and rear within the next month. I wheel quite a bit on local trails but from what I've read most people with NP208's have no problem with similar setups. I don't plan on running a more powerful engine than the 6.2L diesel, and I like the lower gear ratio the NP208 provides (especially with the 37's I'll be running soon). But if I have to replace my NP208 again in 4 years I might as well just upgrade to the NP205 now. So did I just get a faulty NP208 from Boyce in '08? What would you do... replace the NP208 with another, or go through the trouble of putting an NP205 in there, sacrificing the lower gear ratio?
Also, anyone ever mess around with the rear M1008 spring packs in order to get better flex without losing ride height?
Thanks Fellas, I look forward to your opinions.
 
had my own 208 do the same thing. and read of others also with the problem.

if me i would find a 241 case bolt in and much better design.

if not then its 205 swap and you need adaptor/round 6 with long input 32 spline / driveshafts / shifter linkage stock or greattime to do twin stick and modifyed shift rails on 205 before install.

me my self i run only 205 and all 1 tons so thats just me.
 
I have a 208 and have beat the living $hit out of my rig. The only thing I have not replaced is the 208! I run 38s and 42s too. I would think you could find one a whole lot cheaper than $450.00 though. Find one in a junk yard. Heck, I would bet depending where you live 90% of people never even use 4 wheel drive.
 
put a 203 on it, I think you can put the 203 on the 208 adapter with some drilling, at least I think thats what i was told when I was hot to find everything for a doubler...which you could do also is run a doubler

please correct me someone if I'm wrong
 
I use 4 wheel drive quite a bit in Colorado while trail riding. I like to put my truck hairy situations :D. I found a few options, quick question... does the NP241 use the same adaptor as the NP208 to hook up to the TH400?
 
I had one 208 I beat the snot out of and that 208 couldnt do any wrong. Eventually the bolts came loose and it broke off when I was jumping it. Prob my own fault.
Broke another but that was cuz a broke leaf spring pin.

I would say best option would ne a 241 or a 205 for your case
 
I have a twin sticked 205 in mine that I will be taking out to put my doubler in. You would have to locate a 400 adapter and make sure your shaft is right.

It is a figure 8 version.

I would keep it but I am swapping to a 400 turbo, 203/205 that is all ready to go in.
 
i would say 241 i have beat on mine with 35's and i drop the clutch at 5500 rpm and i even cracked the case when i high centered welded it up and still going strong
 
I have a 208. It's did the same thing.A while ago I took it to SCAAMCO & paid a butt load of $ to have it rebuilt. Now that the 1 yr warranty is expired it is doing the same thing again.

...so I took a peak under the there and saw that the bolts were coming loose! I dented the skidplate and wrapped it around the 208 bottom.
oh well,
I'm gonna tighten up the bolts, top off the fluid and continue to beat the crap out of this pig till it squeals.
 
Melbatoast said:
I use 4 wheel drive quite a bit in Colorado while trail riding. I like to put my truck hairy situations :D. I found a few options, quick question... does the NP241 use the same adaptor as the NP208 to hook up to the TH400?
Click to expand...

What he said?

Also, I'm sure I missed it, but what years 241 have mechanical speedos?
 
Also, the 208 and 241 are completely interchangeable as long as they have the input gear to match the transmission (32 spline in this case).
 
I could care less about a speedometer, haven't had one for years. With a 6.2L if I get caught speeding I might get issued an award instead of a ticket. Found a good deal on a local NP205 from 63chevyll. I might go that route and be done with xcase issues for a while.
 
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