I've got this dilema that suprisingly has got me and everyone i ask, including a couple mechanics, stumped. In the fallmy transfer case that was on the truck when i bought itgot a bad crack in the housing from who knows what. So i took it in to a trans shop and they replaced the entire case and put in a rebuild kit too. So i figured i was all set, but the other day i noticed the dreaded black spot in the driveway so when i looked under i found the case was cracked again. What coulda caused the case to crack again in less then 6 months? It's not like i go drag racing or dump the clutch all the time and i only sparingly used the 4X4 in the winter. If anyone has any ideas of what it could be and/or how to prevent it that would be awesome. I also wondering if there is a different, beefy'ertrans/transfer case combo that would fit in there. I've got a 97, 5.2, 5spd, 4X4. Thanks ahead of time, Matt.

 

measure ur tires i have a hunch, dont go by the size on the tire take the wheels off and use a flex tape..

 

will do. what exactly will i be looking for?

 

if you have one or more that are smaller or larger this COULD cause this

 

Is anything loose on the front end, like the axle, springs, shocks, etc...? I have had experiences in the past where transfer cases were cracked as a result of the front driveshaft being pounded into them. If my scanner worked and I found the pics I could show you some pics of this.

 

Tire diameter differences shouldn't make any difference at all unless you're driving on hard terrain in 4wd. Look for loose stuff, broken engine/tranny/tcase mounts, etc.

 

all my tires measured up to the same diameter. The problem actually turned out being the local mechanic who was doing the work. He rebuilt it again under warranty so when it was done i drove it from their shop to a buddy of me and my dad's shop. He looked at it and said the speedo gear had almost no teeth left and the case was full of shavings. So for a trans shop to over look something as vital as a case full of shavings well, f*** em. Thanks for all your responses and concerns.

 

wow! isnt a national chain is it?

 

Tires wont break a t case unless youre runing some huge tires and lots of power.
Most likely its a bad tranny mount or motor mounts thats allowing the drivetrain to flex .
Rob

 

^^ ive done it and no it doesnt take a lot of difference...sliced a tire in my jeep, replaced it with the same tire size ect, ceptfor it was new the others were about 50%granted it was full time awd but it would do it on a dak too...