Transfer case compatability/ other issues
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4wd Low
Joined: Apr 2025
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Transfer case compatability/ other issues
1980 F250 Light Duty 4x4, with a transfer case (208f) problem. Makes almost a “grinding” type noise at around 1300 rpm in any gear (4spd manual) and refuses to shift from 2H to 4H and will grind and make a horrible sound if you try to. So from my understanding something’s F’ed up with it and I think it will be cheaper to replace it with a $200 used unit rather than have it rebuilt for $600 or so. So my question what other transfer cases can I put in it? 208’s are hard to come by in my area.
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Joined: Jan 2001
Posts: 56,966
Likes: 2,728
From: Virginia
Are you trying to shift on the fly or sitting still? The hubs must be locked in and working to be able to shift on the fly. And the hubs do not always work properly.
For your compatibility question, all Ford transfer cases will bolt up to all Ford 4x4 transmissions. The bolt pattern is the same, the spline and shaft size is the same. Except when you get into the later 6 speed transmissions, they are different.
What you have to watch out for is the shifter. If you are getting something different, make sure you get the shifter with it. Or look it over very carefully and make sure you can modify your shifter to work. And one other thing you need to look for, there are two main types of transfer cases. 1. With a fixed output yoke, 2. With a sliding or slip output yoke. You need the proper type so your driveshaft will fit. Most all the different brands of transfer cases that Ford used, could be had in either output type.
For your compatibility question, all Ford transfer cases will bolt up to all Ford 4x4 transmissions. The bolt pattern is the same, the spline and shaft size is the same. Except when you get into the later 6 speed transmissions, they are different.
What you have to watch out for is the shifter. If you are getting something different, make sure you get the shifter with it. Or look it over very carefully and make sure you can modify your shifter to work. And one other thing you need to look for, there are two main types of transfer cases. 1. With a fixed output yoke, 2. With a sliding or slip output yoke. You need the proper type so your driveshaft will fit. Most all the different brands of transfer cases that Ford used, could be had in either output type.
FTE Legend
Joined: Nov 2015
Posts: 30,860
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From: Angier, NC
The shift on the fly is only in high range between 4x2 & 4x4 with working hubs locked like DaveF said.
Also the front & rear axles HAVE TO BE turning at the same speed. If you are spinning the rear wheels and go to shift into 4x4 it will grind and not go into 4x4.
I would never try and shift into low range when moving as I am sure bad things will happen.
Dave ----
Also the front & rear axles HAVE TO BE turning at the same speed. If you are spinning the rear wheels and go to shift into 4x4 it will grind and not go into 4x4.
I would never try and shift into low range when moving as I am sure bad things will happen.
Dave ----
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