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Old 04-09-2019, 09:36 AM   #1 (permalink)
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Cracked gear driven transfer case?

I tried searching with no luck....

A friend and I both experienced the same crack in our gear driven transfer case on the same ride in the same day. Both are setup the same with 22RE / W56 / dual cases / 4.7 gears in the rear case / Trail Gear cross member skid plate / square front driveshaft.

The crack was on the outside of the drop to the front output just above the drain plug.

I rarely post anything so it may take a few tries to get pictures to attach, any help would be appreciated.

So... Has anyone experienced this issue or know what could be causing it? I feel like it would be a hell of a coincidence to happen the way it did, if they are unrelated.
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Old 04-09-2019, 10:18 AM   #2 (permalink)
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huh, weird. what are your mounts? stock motor mounts and just the rubber mounts on the TG skid?

any chance your front driveshaft is a bit long and bottomed out?

any chance you spend decent time grinding the front square shaft on rocks? I've seen trucks bounce on rock from the square shafts hitting the corners and flats with the whole weight of the rig on them.
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Old 04-09-2019, 11:41 AM   #3 (permalink)
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Mine is running all factory rubber mounts motor and tranny. My buddy is running all the solid bomb proof mounts.

We were both beating on them pretty hard and I am sure we could have gotten into the driveshaft at any point.

I know that my buddy was having issues with his front driveshaft bottoming out, that is the reason we built the square shaft for him. That was my first thought as well, bottoming out caused his to crack, but after I found mine cracked in the same spot I began to think it may have been a known issue I had just never heard of...

Last edited by ccantr10; 04-09-2019 at 11:43 AM.
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Old 04-09-2019, 12:09 PM   #4 (permalink)
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Maybe your front axle has more droop than your driveshaft will allow it to do. Are you running a single u joint at the t case side?
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Old 04-09-2019, 12:57 PM   #5 (permalink)
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They do both only have a single joint at the transfer case...
I need to look at that closer, sounds like it could be a possibility. I have cycled mine on a lift but if it is flexing and the driver wheel is stuffed it could be over extending the joints range of motion.
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