I've got a problem with my transfer case on my 85 chevy 3/4 ton 4x4. It's got the 208 transfer case and 400 turbo tranny. I'm not running a front driveshaft right now. When I go to stop sometimes, the truck seems like it goes into neutral and will not move. I can hear this clattering noise coming from the transfer case. I have to shift into 4hi or low from neutral. Then pop it in drive, then shift back to neutral and shift into 2hi. Then pop it back in drive and it takes off like normal. This only happens if I am going fast and stop really soon not allowing the tranny to downshift slowly. I can stop it from doing this by putting one foot on the gas and one on the brake until it stops keeping the idle high. Once I stop I can let off the gas and it's fine. It will take off like normal. What could be the problem? Is it an easy fix? Where can I get the parts to fix it?

Originally posted by 85chevy4x4
I've got a problem with my transfer case on my 85 chevy 3/4 ton 4x4. It's got the 208 transfer case and 400 turbo tranny. I'm not running a front driveshaft right now. When I go to stop sometimes, the truck seems like it goes into neutral and will not move. I can hear this clattering noise coming from the transfer case. I have to shift into 4hi or low from neutral. Then pop it in drive, then shift back to neutral and shift into 2hi. Then pop it back in drive and it takes off like normal. This only happens if I am going fast and stop really soon not allowing the tranny to downshift slowly. I can stop it from doing this by putting one foot on the gas and one on the brake until it stops keeping the idle high. Once I stop I can let off the gas and it's fine. It will take off like normal. What could be the problem? Is it an easy fix? Where can I get the parts to fix it?

It sounds like the T-cae chain is stretched beyond "norm"....IE:tear it down and put new one in. Make sure your trans. is not the problem....drop the pan and look for "glitter/black chunks"....

Are they easy to rebuild? Where is the cheapest place to get a rebuild kit from?

Originally posted by 85chevy4x4
Are they easy to rebuild? Where is the cheapest place to get a rebuild kit from?

call National Drivetrain & see what they can do. It's faily simple to replace the chain if you have confidence in your wrenching abilities. Good Luck....

shift fork problems are common with these cases also, the forks are aluminum and they have plastic pads that contact the sliders. the pads fall off and the forks wear which causes the slider to not fully engage, it pops out into a neutral position (you don't go anywhere), then you have to push it in gear again to move. by dropping the rear driveshaft, you can remove the rear half of the case to check it out.

The problem is you have a shift fork that is worn out. It is caused by: (probably all three)
1) your linkage from the shifter to the case being out of adjustment.
2) Your motor mounts and/or tranny mounts being worn out
3) You have some bad body mounts (which is seriosly amplified by a body lift)

Whats happening is that when you brake hard the body is moving more than the drivetrain, and being as how the shifter is bolted to the body, it is pulling the case out of gear, which isn't too hard when the fork is worn out. Its a common prob. on Chevy's with worn out mounts. Its not hard at all to fix. It can be done with the case in the vehicle. I did mine about a year ago. A new range fork cost me like $50.