4x4 Shifter pops out

[O-Dub]

I have a 78 Chevy k20 with Warren hubs, I can lock the hubs and get inside the truck and put it in hi / low no problem. It is in 4WD but as soon as I drive it pops out, unless I hold it in place. No grinding or noise it just pops out. Thanks for help.


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[shiftpro]

Oh-Dub!
Thanks for joining and welcome Oliver.
You have a transfer case that needs rebuilding. That's an easy job. Well... it's easier than removing the actual gear box.

Do you know which transfer case you're equiped with? Have you been under the truck to look at your linkages?

 

[dvdswan]

Welcome to the site. What @shiftpro said.

 

[O-Dub]

Oh-Dub!
Thanks for joining and welcome Oliver.
You have a transfer case that needs rebuilding. That's an easy job. Well... it's easier than removing the actual gear box.

Do you know which transfer case you're equiped with? Have you been under the truck to look at your linkages?

I can look but is the factory one, all 78 parts. I am handy with my tools so I should rebuild it or have it done. Easy project you say?


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[Shorty81]

Welcome from the Buckeye State.

 

[O-Dub]

Oh-Dub!
Thanks for joining and welcome Oliver.
You have a transfer case that needs rebuilding. That's an easy job. Well... it's easier than removing the actual gear box.

Do you know which transfer case you're equiped with? Have you been under the truck to look at your linkages?

It is a 208C 1982 (someone replaced the stock one)



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[Shorty81]

I had a 205 transfer case that would always pop out under a load, usually trying to get loaded hoppers rolling. I didn't rebuild it, just bolted in another. I had a 208 in another Chevy that committed suicide when the chain broke just driving down the road in two wheel drive.

 

[shiftpro]

Start with pulling your front driveshaft. See what happens.. It's going to need to come off anyway.

Low range is everything normal?

 

[Blue Ox]

Oh-Dub!
Thanks for joining and welcome Oliver.
You have a transfer case that needs rebuilding. That's an easy job. Well... it's easier than removing the actual gear box.

Do you know which transfer case you're equiped with? Have you been under the truck to look at your linkages?

Wait a second,... You're selling this guy a rebuild and you don't even know which transfer case he has?

Do you work for a transmission shop?

 

[shiftpro]

Wait a second,... You're selling this guy a rebuild and you don't even know which transfer case he has?

Do you work for a transmission shop?

They all cost about the same anyway. Oh btw, I found you a bridge...

 

[O-Dub]

Start with pulling your front driveshaft. See what happens.. It's going to need to come off anyway.

Low range is everything normal?

I will try low and see, thx!


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[steveopk]

I had is same problem after replacing my body bushings and adding a 1” body lift, my problem was just the transfer case shifter linkage was out of adjustment after moving my body around on my frame, might be worth checking out before rebuilding/replacing transfer case...

 

[O-Dub]

I had is same problem after replacing my body bushings and adding a 1” body lift, my problem was just the transfer case shifter linkage was out of adjustment after moving my body around on my frame, might be worth checking out before rebuilding/replacing transfer case...

Thank you, I can hold it in 4W high but it pops out right away (no grinding) BUT I can get it into Low at all, it just won’t go either standing still it moving slow


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[rpcraft]

FWIW in most cases you can find an old used unit for next to nothing. You just basically have to know what you have to know what to put back into it. If you have a half ton unit then you will want to replace it with a half ton unit. If an NP208 with a 27 spline input shaft then you can usually find one of those at most salvage yards for around 75 to 150 bucks and if you are handy under the truck you can change it out in a few hours. Just make sure and change the fluid to start with and then you can just swap it and go...