well honestly for your last problem ...
i think buy swaping tcases somanny times you weakend the tail of your tranny, it looks like it had cracked , i know u said it fell in the dirt but the dirts not what im looking at...

what happend during 2nd and 3rd t cases post cracking

 

They were removed and returned

 

i ment to say before... not post... lol

 

i just went over this thread again and it looks like 2 problems ... 1 the t case is blowing up and 2 your 4th and cerberus 2nd problem was from weakening the tail of the tranny when removing the tcases...by any chance did you guys use a jack on the tcase when u pulled them?

 

Not sure what you mean.. There was no weird noises or anything coming from the case.. Just so happend to notice fluid dripping each time and they were cracked.. I used a motorcycle jack when removing.. Jacked it up to right underneath the case and removed the nuts and slid it out onto the jack.. Never jacked up on it.

 

could shifting into 4hi have caused your 2nd and 3rd to crack...? i know u said your front driveshaft was out for the last one but was it in on those?

 

Yea my driveshaft was out for about a month before my first case went bad.

 

so the crackings not from 4x4... were you doing any burnouts?

 

I did a few but the last one was about a month or so before my last case.. NO burnouts on previous cases either.. No other issues either.. This was a sudden thing

 

well something in 2 and 3 caused it to crack in the same place looking at your pics... should have tooking one of them arart to see what caused the cracks