My son now drives my old 1998 Dodge 1500 5.2l that had 190k flawless miles on it...til he was driving home on the interstate last Monday night and the transfer just busted and went all to pieces on him. I went and picked him and the truck up on a trailer and got it to my mechanics shop. We found and bought a good used transfer case and had it installed. The truck made it maybe 10 miles before something caused it to bust the housing between the transfer case and the transmission. WTH has caused these sudden issues?
My mechanic is not the best 4X4 guy around and can do great general repairs/ replacements. What can cause the failures all of the sudden?? Gonna try and post pics of the original case and the pic of the end of the busted housing.

 

Well, the original case seems to have suffered a snap ring failure.

The replacement case ALSO sounds like it suffered the same failure. Snap rings are known for breaking on these t-cases and when they go, they are a time bomb that, when it explodes, takes most of the case with it.

 

Looks exactly like mine!!! I wish I could tell you the solution but I have gone through 4 cases so far with almost the same exact failure.

 

I know what your problem is:


the



SHEAR AMOUNT OF MANLY POWER the 360 makes.

 

lol thats my guess.. Got MO powa den one of dem Cummins V-6 motors

 

Daggone...then the 318 in ours really kicks some ****! Is it possible that the front axle is engaging (on it's own) while the transfer case is still out (not engaged) and could this cause the failure(s)?

 

Got any vibrations in the front end? Bad u joints will rattle it apart

 

The vibrations could cause it. But with my failure almost Identical to his I dont think that is the problem since my front driveshaft has been out of the truck since 2010... Its very possible it was a snap ring issue..

 

Chain and snap ring failure here. And yeah these 360's can pack QUITE the punch, ranking up with the Cummins V6 somedays... Hey, in 1996 the 360 was rated at more than the Cummins HP wise... Not torque but that can be and has been improved.

 

SO, no one thinks that it's possible that the front axle is engaging (on it's own) while the transfer case is still out (not engaged) and could this cause the failure(s)? Snap ring failure(s)??