Anyone else break their transfer case?

[rkcrawl]

[quote=f5fstop]

Originally Posted by Hummie2

Is there any manufacturers who produce a Cast iron or some other type of Steel housing? Yes, AAM makes the identical axle in cast iron

Just MY opinions on this issue

The above is good info... that means there is a direct bolt in replacement made of what should be a higher strength (albeit heavier) replacement. I'm sure that the aluminum case was used for weight savings, but if its proven that case deflection is whats causing this issue, it was a bad choice.

Originally Posted by f5fstop

I fought housing flex in certain Dana 44s (they are not all cast the same) before. Bottom line: when I reinforced the housing and stopped the flex(distorsion) I stopped breaking ring & pinion gears. I did the same, and I ended up busting axles. Every part of the drive train has a weak link, something will break if too much torque is applied with too much weight and too much restriction, in my Jeep it was the axle shafts. Personally, I would prefer the shafts, easy to replace in the field, and inexpensive.

Any of us here who has seriously wheeled has broken more then our fair share of parts. I've busted R&Ps, 9" ford cases, bent housings, axle shafts, transfer case output shafts, driveshafts, etc. I eventually ended up with Dana 60s front and rear, then my axle problems went away (in that rig... )