pt.3 How to full tear down and reassembly of a NP208 Transfer Case. 22 Steps

[@williaml3452]

Your videos are enormous help. But like most geniuses at what they do, you take for granted that we know as much as you so some detail is omitted. Like when you put the planetary gears in - I know they have to be finagled so it fits into the selector lever. You dont show that. Or when you are assembling seals and (thrust) bearings / washers, you speed the camera up and skip details. I figured most of it out and your video is still awesome. Thanks for making them.

[@TheLugnut]

Thank you for your kind comments. It is terrific to hear the feedback about speeding up things I saw as basic. As I am very new to the video and editing part of KZbin. I was trying to keep it within the "recommended ideal" times without totally skipping steps. I have several more videos I am editing. Would you think for things like the installing of seals, would it be helpful to stop explain the process of exactly what I am doing and the risks? Then speed it up. Or keep it slow and make it say 5 videos instead of 4?

[@DNAphotography22]

The one part I needed you to install you didnt have in this video... But overall a good video.

[@horsewithnoname7077]

Thanks for your video, you sped it up and slowed it back down when needed. The music gives it a good touch without being a distraction. Nothing wrong with my NP208c but after watching your video I think I’m going to tear it apart for a SYE install. Hopefully it will go as smooth as your video.

[@tonyuno4253]

I just wanted to apologize for "thumbs upping" Joe Vreelands' comment. Somehow i got confused watching someone elses video who had way too much music, sped up footage, and skipped all the critical steps. Your video is 100% awesome, professional approach, and nobody can even mess with it. I plan on step by stepping this video this upcoming week!

[@TheLugnut]

Thanks for the feedback. I am working on a bunch more videos and making sure the audio is better all around.

[@NoPaintGarage]

Thanks for taking the time to make these videos. Very helpful

[@jonnysprojects6549]

Just a tip but if you freeze your bearings for a couple hours they drop in without having to pound on em too much 👌

[@TheLugnut]

Thanks for the tip. That is great information.

[@jonnysprojects6549]

@@TheLugnut anytime n that was great content 👌👍

[@cumberlandfleetservice6152]

Love the challenger

[@Nowayjose-z2r]

Suggest using what fluid your using instead of Vaseline. I use a squirt bottle (used in body shops to clean paint guns), or a old school pump oiler. If it uses auto trans fluid can use assembly lube for auto transmissions too.

[@chrisw7975]

My main shaft has a really thick snap ring, with a thick notched washer / dowel on the other end that does not allow the gear to go on at the end with the chain. I have to assemble it first before putting it in. These snap rings are a PITA to remove too - even with a 16" set of snap ring pliers. Would love to see how you pulled them so easy. Love this video - reference and watched it ALOT - but there must be several different modes of spacers, etc NP used as mine is slightly different and I have spotted other vids (not as good) that are also slightly different. Thanks for making this.

[@TheLugnut]

I'll look to see if I have the footage of that. As for the snap rings. I have a really good set of OTC ones with deep grooves. One of the tricks is using a pick or a very fine flathead. I get the snap ring out if the grove. Then stick the driver into the gap. Then I stop and regrip the snap ring with the pliers and slip it off.

[@yafois988]

1. The seal & bearing install tool. 2. The bearing puller tool. Where are these same ones available? What you have works so I’de like to copy this. Outside this , the tools listed like the mm sockets and impact, this project looks straight forward . thx

[@TheLugnut]

The 3 jaw puller I don't remember the brand but it's a 3 Jaw Inner Bearing puller. The installer set is a Lisle 12600 Bearing Race And Seal Driver Installer. Both are available at most parts stores. One tip that was mentioned in the coments was to freeze your bearings and the will install easier. Good luck with your project.

[@williaml3452]

On the downside of getting my 208 back together again - thanks to your video. It all went in as shown - only difference was I used grease instead of vaseline as it got too soft at room temp and the whole mess would fall out. When I test fit the 2 halves before using the gray permatex, the chain would touch the housing. I used a rubber mallet and tapped the main shaft down about another 1/2". It still turns freely - just no idea why it didn't just drop in (EVERYTHING was cleaned and greased). Then noticed the long shaft / spring would hit. So again, used a rubber mallet and tapped it down 1/2". Should they both have just dropped in or is that normal? Thanks again for this - sure saved my keester. :)

[@TheLugnut]

Question. Are you running the round magnetic placed in the pocket at the bottom of the housing? I have had them hang up and used a mallet to get it all seated. Turned out the magnetic was hung up and I ended up breaking it and I had to replace it. The other thing it the shift shaft sometimes gets hung up. And tapping it home just seats it into place.

[@RK-iw8jz]

No mention of the tail shaft bushing? I don't see it in any kits.

[@robertkuhn6069]

Great video. Will be rebuilding my NP208 this summer. Kept popping out of 4H will plowing this winter. What was the grit of the abrasive wheel you used to clean the case half and tail housing mating surfaces? Thanks!

[@TheLugnut]

I use a burgundy 3m rol-loc typically on case halfs like these.

[@kuhnzoo]

@@TheLugnut Sorry to be a pain, but do you have the 3M roloc product part number? I am colorblind and having trouble finding the correct item on 3M's website (don't see a color code for burgundy). Thanks so much!

[@TheLugnut]

@@kuhnzoo NO problem at all. The scotch brite pad style I normally use is 3M ID 7000035849. I use this on Al. case halves and most general purpose cleaning.

[@kuhnzoo]

@@TheLugnut Thank you!!

[@jamesconn8206]

I appreciate your videos, has really come in handy reassembling my 208. I've ran into a problem. I don't have a book or guide to reference either. When I finished my assembly, no matter what position I shift, both sides of the case turn.somehow I didn't get the range fork in the proper position. Was wondering if you could help me out?

[@arturonavarrete1828]

What kind of chain did you use? Roller pin or rocker pin?

[@steelmill888]

What's your flavor of fluid after the rebuild?

[@fabricebarbrau1727]

Hello, At first bravo for your explanation for NP 208 désassembling I’m new owner of a F150, 1983,I need to change my transfer case oil (NP208 F). Could you advise me for oil type Many thanks by avance Fabrice

[@TheLugnut]

You should be using atf for your fluid. Fill to the bottom of the fill hole.

[@fabricebarbrau1727]

@@TheLugnut many thanks, But have you a manufacturer to advise me, I read that ATF dextron III is good? I’m leaving on France and it’s not easy to find it, and i don’t want to break my NP208 Fabrice

[@dylancamp5602]

So I have a problem and I don’t know if I can do this or not I have a 1975 400th 4x4 in my k10 with LSswap had a np203 it went bad my dad is on the Volunteer fire department they have K 20s with the 6.2 diesel 400 turbo trans one of them they sold I got a few parts off before they sold them like the transfer case and drop lunch when I tried to put the np208 in my truck the splines would not fit my 400th has 32 spline but is only 1.5 in diameter the np208 is a 32 spline but 2.88 diameter is there a way to adapt that

[@TheLugnut]

You can replace the input shaft on the tcase.

[@josephakins3756]

How much atf did you put in I keep finding different amounts on Google

[@TheLugnut]

I filled up to the bottom of the fill hole. That's what I was taught when I worked on the lube rack at a GM dealership back in the early 90s.

[@barefootandbeltless]

Did you leave the thrust bearing and washer in place between the input shaft and main shaft? Everything I can read says there is only a bearing there. I would think that would load the bearing too much.

[@TheLugnut]

Correct the washer is not ment to be in there.

[@barefootandbeltless]

@@TheLugnut Thank you for the reply. This would be a nice edit to your video to save damage and confusion.

[@Montana5.9]

Where is the best place to get this kit to rebuild the 208? I’m in the states, not sure if it would make a difference. The truck I’m doing it on is an 87 Dodge as well. Not sure it would be too different either

[@TheLugnut]

The Dodge version internally is the same. From memory the rear output seal is different. But the kit in the video comes with the different seal. If you f Don't have a good drive line shop in your area. I would look at Rock Auto.

[@chickenfoundation9323]

For some reason my planetary won’t come off from the main shaft

[@POLLUSKY]

Hey man, i have a question, can i just split the case to re apply sealant to fix a leak or do i have to remove the til first then the half?

[@TheLugnut]

I am sorry for the late reply. I do not think that will work to properly fix the issue unfortunately. It is very important to ensure that the case half's are free of all old sealant.

[@chickenfoundation9323]

What rebuild kit did you use?

[@jason200792able]

Awesome videos on the squarebody. I'm also a big fan of the pickups. I have an 86 k20 and looking forward to some more videos on yours. Where did you get your mudflaps?

[@TheLugnut]

Thank you very much. There is allot more to come for videos with Scar. Right now I'm sorting out a 70 Challenger with a Hellcat swap. Then there will be more on the Square body. I'll try to dig up the details on the flaps for you.

[@TheLugnut]

Hi Jason. I checked into the flaps and there isn't a brand stamp on them anywhere. They were on the truck when I bought it.

[@jason200792able]

@@TheLugnut thankyou for checking for me.

[@chregu2]

Why don't you use the gasket?

[@TheLugnut]

WOW. Indeed why the heck didn't I use the gasket. I know I had it in my head that the case half's had not gasket and completely overlooked that fact the kit included a tail housing gasket. Great catch!

[@chregu2]

@@TheLugnut oups sorry, my mistake, you don't use them because in the manual it says that you have to use loctite 515 sealant on the surface of halves case and tail housing. So you are totally right. One of the two paper gasket is for using on the transfer case adapter to transmission. Thanks again for your video.

[@russellnc]

thanks for not showing the application of the sealants or describing them, one would think that is important but I guess it is not🙄

[@SurferJoe46]

Too much music and your voice overlay is too weak. You don't really need the "music" anyway.

[@TheLugnut]

Thanks. Read the other comments. Your welcome for the step by step.

[@edwinlipton]

That koolass music fights for attention. What are ya doing?

[@TheLugnut]

Ya sorry I messed up the volume settings. Exported everything realized to late so I can't re do any of the music