I keep breaking front drive shafts in my 2004 dodge ram 1500 with the 4.7 in it. This is probably the 5th one. Here is the info I have. I'm hoping someone can figure this out. I'm at my ends with this thing!

1. If the truck is in 4x4 or 4x2 the transfer case output spline to the front diff spins. (Front drive shaft removed)
2. If I manually spin either front tire by hand the other front tire doesn't move. (Both tires off ground)
3. When I manually spin either front tire by hand I can see the yoke on the front diff turning. I've had the front diff case open and didn't see any shavings.
4. With drivers side tire on ground, I can easily spin passenger side tire by hand.
5. With passenger side tire on ground, I can easily spin drivers side tire by hand.
6. I did notice yesterday that the passenger side CV axle has partially released from the differential spline.
7. Truck is a automatic transmission but a 4x4 floor shifter. (non electric)
8. Truck does not have an actuator.
9. Transfer case model- New Process 241.D
10. Front drive shaft is a Doorman. 300$ range. It supposed to be a decent shaft. (This has a U joint at the diff yoke and CV joint near the T Case).
11. Tires verified all to be the same size.
12. No wobble due to wheel bearings or ball joints.
13. Front end is aligned and drives straight.
14. There are no lifts on the truck, All gearing, diffs, t case, all stock.

The shaft has been in the truck for about 2 months and in 2wd only with no problems. The past 2 weeks we have had heavy snow so 4wd has been on. There are patchy dry spots on the highway, top speed was 45 mph. Very few turns made. Some guys on FACEBOOK thought that could be the problem. I've had this truck for 20 years and that was never an issue but I suppose it could be.



The front shaft propeller joint is is twisting and breaking. Any ideas? I don't think the transfer case out put should be spinning in 4x2 but I could be wrong. This is not and AWD truck.

PLEASE HELP

 

Yeah, the 241 doesn't have a AWD setting. (242 does though.)

Since you don't have a central axle disconnect, yep, everything will be spinning when the truck is moving. The front just isn't powered. There is no physical connection to the rest of the driveline, it just freewheels.

Driving on patchy snow/ice on pavement also shouldn't be a problem If the driveline starts to bind up, you will FEEL it long before anything breaks. (hard to turn, doesn't wanna move, slows DRAMATICALLY when you let off the gas, etc.)

Is the truck lifted at all?

 

Thanks for helping!
Nope truck is not lifted at all, all stock. If I have all 4 tires in the air with the front drive shaft removed, I still see that front output spinning. That's normal?

I'm at a loss, every component I've tried to test seems OK.

 

Yep. But, if you stuck a board or something in there, and put some resistance on it, it would stop.

Are all four tires on your truck the EXACT same size?

 

Exactly the same

 

Then I have no idea what would be causing them to break.... unless front and rear gear ratios don't match?

On those CV joints, though, if the boot gets torn, it tosses all the grease, and the joint explodes shortly thereafter. Usually, I would think you would hear it before it actually blows up.... but, if it's dry, and not under power when it reaches its limit, you probably won't hear it. (unless you drive past a build or some such, with the window down. Maybe.) Loud exhaust would mask it to.... Even aggressive tires might....

That said, dorman isn't exactly known for 'quality' parts.... I might be tempted to take the shaft to a driveshaft shop, and them put a new CV and boot on there, of better quality..... and see what happens.

 

Do you have a recommendation for a better brand? I tried to stay away from the Amazon 150$ price range. U may be onto something as everything else seems fine.

 

Tom Woods double cardan

 

Is that a brand? It sounds like they make a double u joint shaft? This gets rid of the propeller/cv joint?

 

This?