I've replaced the tcase once about 2 weeks ago after it cracked. Did the replacement myself, and triple checked all of my nuts and bolts, checked all of my fluid, everything was perfect. I was driving today and dropped my rear driveshaft, I changed out the u-joint with no problems, put it back together and took off again. And then something popped real hard, the driveshaft dropped again, and the tcase is cracked around the tail shaft of it where the driveshaft goes into the tcase. Anyone got any clue what might be happening?

 

my next step would be to check the rear diff.

 

I picked a mechanics brain about the way my driveshaft dropped, and he said it could possibly have been the wrong sized u-joint. Which would explain how it fell, and then the wrong angle on the trans-case was the culprit of the crack.

 

Take that little tail housing off and see if the snap ring is still there. I would bet it's not.