I have a NP208F transfer case out of a '85 F150 that is done past the point of screaming for some TLC
From what I can tell it stress cracked at some point and was a perpetual leaker.
Eventually had to run it in 4H with the hubs unlocked as it would not 'sound right' in 2H
It was not the daily driver so I was in no hurry to take it out for repair. Pictures of the Tcase
I wasn't planning on replacing the chain, but I wanted to get some opinions on the amount of slack there is in it - Slack Pic
. Finding an overhaul kit has turned into a major undertaking as no one seems to have them in stock and different places have different amounts of stuff in what they call their 'complete' kits.
Slack too much? Are there specs for the slack - I have not been able to locate any specifics nor have I seen the innards of a case with a new chain. I have repaired the case crack - will have some pics posted of that later on. I stop drilled the crack to keep it from spreading and used an angle grinder to dig an angled channel along the crack and brazed it with some aluminum rod specific for dirty aluminum/magnesium alloys. Survives hammer blows, but will have to see if it holds up to the torque from my 302.