205? transfer case problem

[gotsmeuhh350]

My 86 k10 (350,700r4/205) has an issue with the transfer case and its been driving me crazy. I believe its a np205, as its not full time 4x4. (havent had the time to crawl under it) What happens is if im driving and i have to hit the brakes hard, it makes a quiet ticking sound, not very loud, but just noticable.
And it puts the transfer case into neutral. the transfer case shifter doesnt move, so it switches gears internally. i can give it as much gas as i want and it wont go anywhere. i can put the tranny in any gear, and nothing happens. until i go through all of the gears in the transfer case. then i put the truck in drive, and itll drive again. it makes me angry, because if a guy in front of me hits his brakes hard, and i have to stop, i have to pull over, put the truck in neutral, shut it off, go through the transfer case gears, start it up, and then drive. it would really help me out if anyone could figure this out, because im stumped. should i just look for a new transfer case? get this one rebuilt? i have no idea. or is it  something that can be fixed?

[76k104x4]

i had that problem with a 208 in my old 82 but i totaled the truck before i could fix it

[Irish_Alley]

to me sounds like a rebuild or swap it out.

[gotsmeuhh350]

yay. lol. my truck doesnt have back brakes if that helps.

[bake74]

     You need to crawl under and look at the transfer case and yolk.  I am wondering if when you stop quick the mounts are not that good and it is flexing, also make sure your rod that shifts is not weak and maybe flexing, otherwise I am with everyone else, time for a rebuild.

[1979C20]

Youre sure the shifter doesnt move? You may need to check the shift linkage for any slop and also make sure the shifter isnt hitting the hole in the floor

[Irish_Alley]

if it did pop out why would he have to cycle threw the gears in order for it to find a gear? I could understand if he just had to select a gear and go but why find all gears before he can go

[gotsmeuhh350]

im positive it doesnt move. it happend twice today also. im not sure what is wrong with it,
but ill check all the linkage tomorrow. thanks.

[1979C20]

Sounds like maybe the internal shifter fork is going out. Maybe the shifter fork roll pin is letting go? And it may also be the shift rail(s) being worn out and making it pop out of gear  on the top of your transfer case there is a bolt(not sure if theres two) and under the bolt is a spring and a ball bearing. Thats your detent ball, it rests on the 3 groves of the shift rail and it helps keep it from moving when its in gear. That spring could be warn or maybe even missing. And the 3 grooves(hi, neutral, low) could be wearing down causing it to pop out of gear.

[gotsmeuhh350]

is that something i can check while its still in the truck, or will i have to drop it and check it out? i mean the detent ball, not the shifter fork.

[1979C20]

The detebt ball, possibly. Its on the top of the transfer case about the shift rod that is closest to the input shaft. You can probably get to it by pulling the floor/doghouse. And the shift rail and shifter fork, no. Youd have to drop the transfer case because the tranny will interfere with removing it.

[gotsmeuhh350]

alright. ill take a look at that tomorrow morning.

[topp]

Uhm...Unless a PO or you did a swap, an '86 should have a NP 208 Transfer case...

[76k104x4]

if its a 208 id definatly just pull it its pretty light compared to a 205

[gotsmeuhh350]

ohh. well it must be. i havent been able to crawl under and check because its either been raining, or its been muddy. i really cant have my truck down for more than a day at a time, but how hard is it to drop a 208? if i can find one at a junk yard, i can rebuild it and replace mine. does anyone know of a good rebuild kit that wont empty my wallet? thanks