Rebuilding the NP208 transfer case

[@TheShadeTreeFixitMan]

I had to chuckle when you noted the mess on the floor after pulling the transfer case out. Back when I first started working on cars in my backyard as a teenager, I wasn't happy until I was covered in grease and dirt... Great fix on your pickup, Dean.

[@Fullthrottle440Garage]

Yeah seems like there is always some kind of mess thanks for watching

[@busman5429]

Dean you sure have skills, great job thanks for sharing the rebuild with us.

[@Fullthrottle440Garage]

Thanks!

[@odahithedubious2017]

Glad to see it's up and running again. All the best to you.

[@Fullthrottle440Garage]

Thanks seems to be holding up good so far

[@nostromo4269]

I put gear oil in my 208. Drove that truck 20 years. Never had an issue with the T-case

[@Fullthrottle440Garage]

Are you sure it wasn't a 205? Just curious. That's impressive

[@lhb4031]

Great video, glade to see you are up and running.

[@Fullthrottle440Garage]

Thanks

[@TheShadeTreeFixitMan]

I wouldn't be surprised to see that the gear oil was put into your transfer case to quiet it down for resale... In the old days if an engine or transmission had too much noise, the used car lots would sometimes put wood fibers into the crankcase to quiet the bearing noise...but that was a very temporary fix.

[@Fullthrottle440Garage]

Probably the case here. I think someone also put real thick oil in the engine to quiet it down. (The 400 that was in it)

[@rob_v_nj]

I have the NP208 in my 84 F250. Its grinding at high RPM and downshifting. It seems positional also, there is a hill i drive and always grinds there.

[@Fullthrottle440Garage]

Yeah probably range fork worn out

[@johnsarian_cu]

Plastic seems like an odd bearing material but I've seen it used a lot over time in things like power tools and other stuff. It lubricates surprising well because it repels oil. Might especially be effective in a bath or immersed. Metals still better if there is going to be a ton of force as you can literally squeeze oil out. Sintered brass is one example. Seeing those that look more like tabs makes me wonder if the goal was just to have easy and cheap wear parts to be replaced though. Not completely bearing surfaces.

[@Fullthrottle440Garage]

Yeah those are probably the reasons they used plastic. The 208 isn't the best transfer case but works fine for medium duty use. The 205 is what you really want

[@macharleys72]

Is there anything you can’t work on?! Nice work, saved yourself quite a bit of cash too….

[@Fullthrottle440Garage]

Well there's plenty I can't do , but thanks!

[@programista_w_garazu]

What do you have under your steering wheel ? I just received my F150 and i have this device too - but i don't know what it is ? (it has PILOT writen)

[@Fullthrottle440Garage]

Brake controller?

[@TheKlamminator]

My 4 hi in my 87 k5 keeps popping out of gear and I'm pretty sure it's that fork. Think I gotta rebuild it

[@Fullthrottle440Garage]

More than likely it's that fork. Super common

[@big_b_dd]

Was yours popping out of 2wd and only way to move the truck in 4 lo? Mines doing when i hit brakes and pops out of 2wd

[@Fullthrottle440Garage]

Yeah that was exactly my problem.

[@big_b_dd]

@@Fullthrottle440Garage thanks I know what exactly is wrong with mine now been dealing with it for 4 months now

[@Fullthrottle440Garage]

@@big_b_dd it's definitely that shift fork in there. It's called the low range fork. Pretty common problem I guess. The little plastic guides fall off then it's metal on metal and it eats itself

[@jeremywalker2460]

My 87 is doing the exact same thing, so what was the actual problem?

[@big_b_dd]

@@jeremywalker2460 everything you read above the the low range forks plastic tabs fall off and the forks wears away