I 've got an 85 chevy 3/4 ton 4x4. It was popping into 4wd by itself so i determined it was the transfer case. It's got a new process 208. I took it apart and found that one fork was almost completely gone and the other one was wore. I replaced both forks and reassembled the case. I thought i put it back together correctly but now it won't shift into 4lo. It will go easlily into 4hi but it seems like maybe it's trying to engage 4hi and 4lo at the same time because when i try to shift it in, it goes in, then as soon as i put it in gear it grinds. I believe that i put the spring that goes inside the case in the wrong spot. I put it between the forks and the outide fork, i put the bracket around it but couldn't get the little peg on the end to go in the shift range selector bracket. Should that spring be on the end of the rod that goes inside the gears or the middle? Does the outide fork attach to the range selector bracket? There are about 4 round holes and 3 slots on that thing. I have 3 chevy manuals and all of them are hard to read. I have also tried adjusting the shifter linkage back and forth and nothing changes. Just want to find out what's wrong before i tear it apart again.

It has been awhile since I was in one of these, but I think that the spring goes on the outside of the shift forks. Between the case and the rear shift fork. As for the fork, I don't remember. I will have to get out the ol' Unit Repair Manual :)