208 case hard to enage
I went through this case a few thousand miles ago when I rebuilt the transmission because I found chunks of metal on the plug. Well so I tore it apart to see what the trouble was. Replaced the problem part and replaced one fork because the plastic peices were worn through and wore out the metal on the fork, put in all new plastic peices and tore down the whole case looking for anything bad. Put everything back together and it works fine just a little grinding going into 4lo but that seems to be pretty normal. It doesn't pop out of 4wd in any range but is just hard to get it into 4hi, it will go if you keep messing with it, and once it goes in you can put it in 4lo with no trouble at all. Is there some kind of trick to it or something? This is the first chevy 4x4 i'v owned myself so am not terribly familiar with the working of the T-Case. However I am fairly knowledgable about chevy engines and transmissions.
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