Hey everyone, I've been a long time visitor to these forums though I've never posted because the great feedback usually helps solve any problems I have with my Durango. Anyway, I'm driving a 2001 4.7V8 4WD Durango SLT with the 45RFE transmission going on about 220,000 miles now, with the only major note being that I blew my engine around 200k, so I've replaced the engine and transmission from a near identical wrecked Durango that had about 80k miles.

(I'd like to note in advance that I had no knowledge of the signs of wear and damage associated with a transfer case before all of my research tonight)

After some time driving with the replacements, I notice a slight clank sound coming from what sounds to be the areas of the drive shaft underneath, I decide to replace my brakes and rotors (no more than two weeks ago) due to this being well overdue now thinking it will solve my problems, and for the most part I get a smoother ride, but the clanking persists and I begin to suspect the drive shaft but have no method to inspect during driving. Not long after this I begin to notice a slight vibration but figure it to be the rotors breaking in, though after a few days of driving it gets no better and I suspect that I over torqued the lugnuts and make a note to go through with a torque wrench when time allows.

All of that changed last night when I was driving home (going about 55, nothing out of the ordinary, still in 2WD) when suddenly the vibrations get stronger for a few seconds before the whole vehicle shakes a bit, followed by a loud clanking sound. Having expected something to happen due to my ignoring of the vibrations, I pulled over and immediately went to check the rotors which are fine, but I notice that my transfer case and front drive shaft were dangling off the cross member, hanging on only by the transfer case chain. And by this, I mean that the entire front drive shaft section of the transfer case had broken off from the rest of it. But I was still able to move the Durango, so I moved to a safer place and called for a ride.

This morning we drove it up onto a trailer and brought it home to take a better look in the daylight, and after a bit of inspection we pull the front driveshaft off along with what was left of that section of the transfer case. Here are pictures from underneath of what was left after removing just those pieces (yes, the chain is held up currently by a wire):




And then the pieces we pulled off:




So far I've got someone telling me that this happened because of running with next to no fluid, which is most likely, as I never filled this transfer case with fluid after the engine and tranny swap after they had been sitting for a long while. Another theory that's scary to think is possible is that the transfer case has been trying to engage in 4 wheel drive on its own lately, as the teeth on the gears are scarred, but I'm not sure how likely this is.

Now here's the part where I'm looking for a bit of help from people who know quite a bit more about this than I do. In this state with these parts removed, the Durango is still completely drivable, with no noticable sounds, vibrations, or leaks. Although I have every intention of fixing this like yesterday, (I know this will seem completely stupid) I'm curious as to whether or not driving like this will lead to further damage of anything else? My nearest estimation of being able to work on this could be either Friday or sometime next week, and I'm just wondering if the Durango would be able to keep driving problem free if I absolutely had to drive it more. Again, this is just my curiosity getting the better of me because I would expect a vehicle with a grenaded transfer case to instantly be immobile, and in all my searching I've not found anyone who removes the front drive shaft and still attempts to drive.

Also, when I do replace the transfer case and front drive shaft, are there any gaskets or seals I should replace? And what should I look out for when making the swap? I've read up a little bit about other transfer case replacements and they seem straightforward enough, and my old transfer case is the same exact part number (233D, I believe) and is the part I intend to replace this mess with, along with my old front drive shaft. Any help or comments would be greatly appreciated, as I've not had much luck in locating replacement guides for this particular part on this Durango.

Thanks in advance, and if anyone wants any more pictures or info, I'll provide as soon as I can.