So...what happened?

[Fordeatinz71]

well, ever since my truck lost it's rear u-joint at freeway speed my t-case has been acting up.  last night after i got home it started making clunking sounds like something was trying to seize but was breaking free, which obviously worried me.  today, i go to go to work and it's clunking loudly.  i get ready to turn back at the end of my road and make half the turn and it starts grinding and ceases forward movement.  i put it in 4Hi and get nothing, then i put it in 4Lo and thankfully that works.  i slowly drive it home and when i get back in my yard i put it in 2Hi and it started moving again...did i mess up the range forks?  anyone know if this is something that can be fixed relatively easily? 

[VileZambonie]

Do you have manual or auto locking hubs? Which transfercase do you have?

[Fordeatinz71]

auto locking hubs and an NP208...doing more reading i think the range fork wore out...either that or it's low on fluid, which also makes these 208's jump outta gear...

ya think it's too late to put fluid in it if it is low?  i'm thinking i'm gonna try it anyhow since it's not like it'll really cost me much...

[VileZambonie]

Get rid of the auto locking hubs

[Fordeatinz71]

they're on the list...lol.  but i'm pretty sure this problem is in the t-case, not the hubs...

[VileZambonie]

Are you sure it's the transfercase? Jack it up and run it and listen with a stethoscope.

[Fordeatinz71]

oh yea, it's the t-case.  i found a crack in the tailcone and JB welded it (i know, i need a new cone but for right now at the moment that stops the leak, and it's aluminum and not under pressure so it doesn't hurt.)  i filled it with transmission fluid and took it for a ride.  it sounded fine for a little bit, then it started clunking slightly, then louder...and then it kicked itself out of gear...i had to put it in 4Lo to get it moving again.  but as soon as you put it in 4Lo you can put it back in 2Hi and it will keep moving for a bit.  so now i'm gonna keep an eye out for a NP205, i'd like to upgrade.  if not, i'll rebuild this pig...

[VileZambonie]

Just get another 208. they are plentiful! I have 3 or 4 spares and a few 241's. I actually like the 241 better.

[Fordeatinz71]

the 241 would be a good upgrade.  i just wanted a 205 because of the gear-to-gear and the heavier duty case...

[Fordeatinz71]

alright, well, a small update of sorts.  i needed to use my truck to ease over to the dumpster so i could drop off some trash.  i decided to start off in 4hi instead of 2hi.  well, it didn't even TRY to jump out of gear.  i decided to take it on the road and see how it did, i was easy on it at first but by the end i was gettin on it pretty good...no issues at all.  so i'm pretty convinced my range fork went bad, i found one for $44 so i think for now (until i find a 205) i'll just fix the carnage in this one and keep going with it.  they are pretty stout t-cases anyhow.  for the immediate time being (until i get time to do the range fork) i'm gonna drop my front driveline and run it in 4hi, because i still need to use my truck on occasion since it is our second vehicle...