I've been working on my 208 transfer case lately. I've replaced both forks, hubs, and adjusted linkage. It will always spin the front driveshaft in 2hi. It whines very loud like it's gonna blow up. I can just lock in the front hubs and can be in 4hi even though it says i'm in 2hi. Also I can't get into 4lo at all. It will grind but won't engage. When I took the case apart I noticed that there is a spring that goes in the case. I put it between the forks. Is this correct? Is there something else that might not be right in the case?

On my 85 chevy it does not spin in 2wd, also mine can be tempermental on going into 4 low try it in park and netrual. As far as the internal components I have no idea.

A little rotation from fluid friction is normal, but you should not have drive power with the hubs locked in. It's been a long tiem since I had a 208 in anything, but 4-lo shouldn't be that hard to grab, sounds to me like your mode and range forks are all forked up.

Thanks for the help guys. It definitely has power going to the front all the time. It whines very loudly at around 40mph. I'm just afraid something will blow up in there. I'm going to remove the driveshaft for the time being until I get to my wheeling spot.

Mine does not move in 2-hi either. I would think that there is a shift fork problem or linkage outta whack. As for the whining, can't be good. Fluid full? Mine goes right into 4-lo, so i am no help there. I would check linkage, find a schematic and see if your assembly with the spring is right, and if nothin, find a spare t-case and throw it in the back of the truck just in case! :D Also, if it does explode, post pics.

I found out what the problem was. My crappy chiltons manual shows the spring goes between the shift forks. I bought a haynes and it had detailed pics of the case. It shows very clearly that the spring goes on the outside of the forks. The last thing to go on before sealant. I took it apart and put it back together like that and it works perfectly in 4hi and 2hi. I still can't get it to engage in 4lo. It just grinds. Something has to be wrong in there somewhere. I did some hard wheeling and it did fine. It would have been nice to have 4lo. Sorry it didn't blow up so I don't have pics of a blown up transfer case.:)

Its a 208 give it some time. My 85 k5 is fiesty going into 4 lo. I have to put the t-case in nuetral, mash the brakes hard, shift into drive quick then back to park otherwise it wont go. Sometimes I even got to turn the engine off. I should probably rebuild it but if the chain snaps and cracks the case I might be forced to get a 205. :)


Charlo

ditto on the 4lo shifting problem. i have to put tranny in neutral, turn off engine, and then shift into 4lo. other than that and some leaking output shaft, no problems! :rolleyes:

I see its been a few months since any of you all have been to this string. But still maybe someone can help me with a few questions. I'm using a 208 behind a 700R4 in a samurai. In order to get clearence covorage from the frame and a possabilityfor it to work for me for a while I have clocked it counter clock wise about 60 degrees. This puts the front output slightly above the threw shaft. What are the lubrication issues i need to look at? Dose this transfer case use an oil pump with a pick up and where is the pick up? Does anyone have a picture of an exploded view or a link to a sight that may help? Tanx Steve

make sure that you are in N or P (most t-cases won't go in to low unless your trans is in N)

if you moving at all the case wont go into low. But if your stopped and it still wont shift sounds like things are worn out. Possibly the syncros.

Try it with the tranny in N and rolling real slow. Like 3 mph or slower and try shifting into 4 lo then. That is how I had to do mine. If I was moving too fast the gears were moving too fast to line up and it would just grind. If I was stopped, the gears weren't turning at all and the chances of them being lined up aren't very good.