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I have a 1984 fullsize bronco with a 351w, c6 trans, and a np208 t-case. The t-case is making a loud grinding noise when i try to put it into any gear. What happened was i was coming back home and when entering town i let go of the gas pedal to slow down and the truck surged a little and made a grinding noise just like when you try to put a manual trans into gear with no clutch a couple minutes later it did it again but this time it didnt stop. Pulled off the road to check what happend. Started the truck again put it in gear same grinding noise when put in gear, shut it off and tried 4wd hi same thing and then tried 4wd lo and it engaged and got home like that. Now it does that in every gear except sometimes it will engage in 4wd lo for a while. Any help would be greatly appreciated.
Your transfer case is toast. Start looking for used ones, or a price for a rebuild. Could be that the mechanic could install a new shift fork kit if the damage isnt too bad.
thanx for the info. I was kinda hopeing it wasnt. I was out working on it today and the t-case fluid was very low maybe a liter and a half was all it had in it and it had metal shavings in the oil. I added another 2 liters but its still down. it engaged in 4wd lo again so i tried 2wd and it engaged again but then after awhile it started grinding again