Okay, so in 4low, driveshaft removed, it stalls? Got to be that t-case retainer then. Just drop the rear shaft, 4 bolts to undo the tail housing. Check it out. It just takes some rtv to seal it back up.

 

I will check that out today. If that is the case, the t saver would do the trick?

 

Yeah, if it's not too far gone.

 

Of course, this still doesn't answer why you keep breaking off wheel studs...

 

How could I tell if there was too much damage done? Like I said, it has snapped the wheel off 3 times, so it's taken a beating.

 

Perhaps the t case and CAD are both bad?

 

Is the RF wheel still locking up with the front driveshaft out? If it is, you need to take both sides apart and inspect it. If not, I think the tcase is the problem. Other guys tcases have grenaded because of the snap ring. I think your shaft moves and locks the front drive shaft while your driving. If that's what's happening, I would buy a different tcase and inspect the front axle and drive shaft very thoroughly. You could have twisted splines, chipped teeth, etc.

 

I have not given it the chance to lock up Since I removed the drive shaft. I havent had it above 10 mph.

 

I definitely think it's locking up the front shaft. For some reason yours locks up the RF wheel instead of grenading the tcase .

 

Since you removed the front driveshaft, it still stalls but does it still break off the studs? If not, maybe the t-case shaft slides, locks into 4wd while driving it snaps off the studs and tire. Maybe the t-case saver is sell you need. I would try it first before swapping in a new t-case.