2001 Dodge 1500 4x4 no lift kit. Bought the truck at an auction. Found out it had a cracked transfer case (Rear part of the case). Got a used transfer case at a pick a part. Had it completely rebuilt and a steel rear drive shaft made for it (the one on it had dents) from a place that builds drive shafts. 4k miles later, the case is cracked in the rear again. The shop is sending the shaft back to check the balance. Is there any other thing that would cause it to crack.

 

Age, casting flaws, abuse by prior owners, lack of lubrication, bad luck.

If you weren't feeling a vibration, likely just the last option.

 

Transfer case saver
https://www.google.com/url?sa=t&rct=...sj0Z26jbUAWH9L

Maybe consider new engine and transmission mounts.

 

Is it housing where the driveshaft slips into the transfer case that cracked? I wonder if it's an absent snap ring issue. like the issue that inspired the transfer case saver to be created.

 

I am going to call the shop tomorrow and ask for them to check my mounts.

 

Just Googled the Transfer Case Saver. I think I will tr ity. As for where it cracked...the backside of the case where the shaft to the rear wheels comes out.

 

Seems odd that two transfer cases cracked. That leads me to think it's the mounts or some other vehicle problem. I have the T-case saver in mine, it's cheap insurance.

 

I replaced one six months ago for an Identical hairline crack all around. This is the second one. Looking for answers on this one. Heavy vibes between 55-65 and when letting off the gas.

 

Is the snap ring still in place on the output shaft?

 

Having it towed I'll take a look when It gets to me.