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Old Dec 8, 2025 | 03:47 PM
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Mountain_anderson
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NP208 Questions

Hi all, I am in the process of rebuilding the transfer case in my 1986 Ford F150. It has an NP208 transfer case and I have a few issues. Firstly, the original planetary gear has not only had its plastic bushing worn away but the steel underneath began to as well. I was unable to find a reputable replacement that has the same plastic bushing. I was unable to find an oem or nos one nor was I able to find a good used one. I settled for the all steel one used in Chevys and dodges, however I learned the fork that grabs onto it is supposed to have the plastic pads on it when grabbing onto the bushing. I only have the oem ford one that is fully cast iron throughout and not notches to accept the plastic pads, however the shift fork built for the Chevys and dodges have the pin used to move the shift fork is in a different position, though it has material built up where the one for the ford pin would go. I am unable to find a shift fork with both notches cut in and the pin in the right spot. So I have two solutions, both seem sketchy in my opinion since this is my first time doing this but what do you guys think.

1. I file down notches in the shift fork to accept the plastic pads
2. I drill out a hole in a dodge or chevy shift fork to reposition another pin, I would find a pin of similar spec and just cut the original one smooth with the surface.

I attached images below. The one is of my current ford shift fork and how the pads should go in, the other is a dodge and chevy shift fork with the notches for the pads but the pin in a different location



 
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