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The Arizona Transfer Case Massacre

alrock

El Diablo
Staff member
Messages
10,673
Location
Scottsdale
Well, I had a couple of clunks recently and some reluctance on the truck's part to shift between 4H, 4L. Last night on the way home from Walmart, there was a giant clunk, a big hesitation like someone stuck a stick in the spokes of my wheels, and a loss of all drive. Pressing the accelerator got me nothing except for some nice revving.

I pulled over on a side street and couldn't get the truck to move. Finally, I put it in 4L and when I put it in reverse it grabbed and then allowed me to drive forward. I drove the last three miles home in 4L, but there was no binding of the front wheels in the turns.

This morning I was able to get it into 4H Lock, again having to first put it in reverse to allow it to engage and then D was available. I was planning on heading to Reloader's house to help H3ATH3N with his H3 but I guess mine was also about to get some attention.

Well, while sitting in Reloader's driveway we noticed this little issue
Transfer%20Case%20072614%20%281%29-L.jpg


We got the truck on the lift and the whole back half was covered in oil. At first we thought the seal was leaking but hmm, the seal looks fine. The oil sure is dark.
Transfer%20Case%20072614%20%282%29-L.jpg


We drained the oil and it didn't come out a pretty red. In fact, it was somewhere between anti-seize and melted Terminator.
Transfer%20Case%20072614%20%283%29-L.jpg


Not very pretty
Transfer%20Case%20072614%20%284%29-L.jpg


Transfer%20Case%20072614%20%285%29-L.jpg


So we pull the transfer case and look what we find! The innards weren't playing Terminator, they were acting like Alien and trying to punch their way out of the gut.
Transfer%20Case%20072614%20%286%29-L.jpg


You can see the bulge in this pic
Transfer%20Case%20072614%20%2810%29-L.jpg


So, naturally we ("we" meaning Reloader) take it apart.
Transfer%20Case%20072614%20%2813%29-L.jpg


Ta da! The transfer case chain went all boa constrictor on us, ripping apart and choking the pieces.
Transfer%20Case%20072614%20%2814%29-L.jpg


Transfer%20Case%20072614%20%2815%29-L.jpg


If you look closely you can see grooves in all kinds of parts from the chain slapping around. The fork had grooves and was even missing a piece of one end.
Transfer%20Case%20072614%20%2818%29-L.jpg


This chunk of Terminator was sitting inside the case
Transfer%20Case%20072614%20%2819%29-L.jpg


Pieces of chain everywhere
Transfer%20Case%20072614%20%2823%29-L.jpg


Transfer%20Case%20072614%20%2820%29-L.jpg


And for those with good memories, you may recall the Audi I had breaking on the way from Walmart to home. Obviously, I should never shop at Walmart again.
 

LagunaH1

Well-Known Member
Messages
3,730
Location
Idaho
Yikes, sorry to hear!

In hindsight I should have asked Mike S to show me the main gear from my T-case that failed. I'm told the main gear was skipping under load and I can't help but wonder what that might look like
 

Zach

Mall Crawler
Messages
4,812
Location
So Cal
It's only missing a few links of the chain right? And why I don't go to Walmart. Nothing ever good comes out of it here. I already have one inbound this week, sorry diggles [emoji41] lol
 

SuperBuickGuy

Well-Known Member
Messages
3,403
Location
Woodinville, WA
before you throw that away, the lower gear looks pristine... I could use it to start the fix on mine. I lost two links off the chain drive, and one got caught in the lower gear - snapping a couple teeth off. Then I'll only be a chain and a shift fork away from a spare 4:1 transfer case.
 

06 H3

a.k.a. "The Jackal"
Messages
9,503
Location
Meridian, ID
That sucks. Luckily reloader has his base case. That's why I keep mine.

Zach to the rescue as always. He's always saving our asses...

I am not sure of the root cause but I notice the fluid on these t cases gets nasty quickly. I change mine every 15-20k miles (once a year) vs the recommended 50k service. I am no expert on how bad fluid affects parts but I try to keep that fluid looking red at all times. I atleast know it won't hurt
 

alrock

El Diablo
Staff member
Messages
10,673
Location
Scottsdale
before you throw that away, the lower gear looks pristine... I could use it to start the fix on mine. I lost two links off the chain drive, and one got caught in the lower gear - snapping a couple teeth off. Then I'll only be a chain and a shift fork away from a spare 4:1 transfer case.
We're sorta doing the same evaluation right now, whether we can easily convert this base case to 4:1. If we end up being too far away from being able to do that I'll keep you in mind to donate parts.
 

SuperBuickGuy

Well-Known Member
Messages
3,403
Location
Woodinville, WA
mine broke the next morning after a night of wheeling - drove nearly 100 miles, but I think it was hitting a log at 20 mph that got me (10" diameter fallen tree). It was not a good night, smacked the rear flare on a tree, then the transfer case...
 

Best4x4

Well-Known Member
Messages
1,042
Location
Vidor, TX
The cause of this was probably slack in the chain, which then let the chain slap around inside the case on all the internal parts in it's path until the chain finally got a weak spot and broke causing the big clunk/bang.

Used to see this issue on older Range Rover Classic's, Discovery Series I, and Defender 90/110's. Pretty much the same AWD setup, but on a Rover it was linkage controlled vs electronic so if you were driving it you could let off the gas, and get back on the gas and if you had slack in your chain you'd hear a little chatter, or if it was badly worn a lovely ZZZZZZzzzz sound as the chain rubbed the case/internals. You'd also see the knob vibrate/rattle. If caught in time all you have to do is replace the chain, and fully flush the case of any metal/aluminum dust from the chain slapping.
 

SuperBuickGuy

Well-Known Member
Messages
3,403
Location
Woodinville, WA
The cause of this was probably slack in the chain, which then let the chain slap around inside the case on all the internal parts in it's path until the chain finally got a weak spot and broke causing the big clunk/bang.

Used to see this issue on older Range Rover Classic's, Discovery Series I, and Defender 90/110's. Pretty much the same AWD setup, but on a Rover it was linkage controlled vs electronic so if you were driving it you could let off the gas, and get back on the gas and if you had slack in your chain you'd hear a little chatter, or if it was badly worn a lovely ZZZZZZzzzz sound as the chain rubbed the case/internals. You'd also see the knob vibrate/rattle. If caught in time all you have to do is replace the chain, and fully flush the case of any metal/aluminum dust from the chain slapping.

you've almost owned and broke as many 4x4s as I have.... very impressive :thumbs:
 

Best4x4

Well-Known Member
Messages
1,042
Location
Vidor, TX
Yeah I started with 2Dr Mitsubishi Montero's, then a POS Nissan Xterra (poor thing was a lemon), finally had 5 Rover's a 94 RRC, 97 D1, 97 RR HSE Vitesse, and two D2's SE/SE7. Wheeled with several D90's but I never found one to buy in my area. Then I went into Jeep's 2 05 Wranglers TJ Rubicon/LJ Sport, and my 04 Grand Cherokee 4x4. Had plenty of trail rash on my 94 RRC, and 05 Rubicon. I had chain slack in the 94 RRC, but as long as you knew you had it, you could baby it by not being so hard on the throttle. My 05 Rubicon had plenty of issues, from broken linkages, flexplate crack, PCM short out on the trail (fun one...), and a few u-joints. No actual failures that left me stranded.

Got extremely tired of the "Jeep" scene after the JK became the new mall crawler, and all our serious clubs turned soccer mom/mall crawler overnight.. Now I am into H3's because I like something different with new mods that are fun and yet again different that everyone else in their clone JK's. From all my rigs I'd say an H3 is like a Jeep/Rover mated which means the best of both worlds if you ask me.

I saw plenty of 231's and a few 241's end up looking just like what happened here. The worse one I saw was behind an RV, and the linkage went from N to 4L and exploded the transfer case so bad it exploded, blew a hole thru the floor, broke both drive shafts, cracked the entire case (more like peeled it open), and even destroyed the exhaust!!

The fluid going black so soon is just the fact it's an AWD setup and it's constantly having to work vs a Part Time system if you ask me. I'm pretty sure my wife's early 07 has the plastic shift fork because it's really quiet shifting from 4Hi to 4Hi Locked, and 4Low vs my 08 Alpha. Gonna go ahead and buy the metal shift fork and get ready to upgrade it one weekend.
 

digglesworth

Well-Known Member
Messages
1,789
Location
illinois
It's only missing a few links of the chain right? And why I don't go to Walmart. Nothing ever good comes out of it here. I already have one inbound this week, sorry diggles [emoji41] lol

All good Zach. Just remember, no matter what Alex says, my adress is in Illinois. Not Arizona... :giggle:
 

jakesz28

Well-Known Member
Messages
1,056
Location
Cabool MO
Love the description of the tear down. Not the carnage, but I guess this shows how hard life can be when going out for groceries. I'm going to Hyvee from now on. Besides they have a better beer selection.
 

rsc

Well-Known Member
Messages
1,087
Location
Tulsa
I hate to hear of the failures, but love the teardown pics. I like seeing whats hidden inside away from view, gives a better understanding of how it all works.
 

SuperBuickGuy

Well-Known Member
Messages
3,403
Location
Woodinville, WA
Yeah I started with 2Dr Mitsubishi Montero's, then a POS Nissan Xterra (poor thing was a lemon), finally had 5 Rover's a 94 RRC, 97 D1, 97 RR HSE Vitesse, and two D2's SE/SE7. Wheeled with several D90's but I never found one to buy in my area. Then I went into Jeep's 2 05 Wranglers TJ Rubicon/LJ Sport, and my 04 Grand Cherokee 4x4. Had plenty of trail rash on my 94 RRC, and 05 Rubicon. I had chain slack in the 94 RRC, but as long as you knew you had it, you could baby it by not being so hard on the throttle. My 05 Rubicon had plenty of issues, from broken linkages, flexplate crack, PCM short out on the trail (fun one...), and a few u-joints. No actual failures that left me stranded.

Got extremely tired of the "Jeep" scene after the JK became the new mall crawler, and all our serious clubs turned soccer mom/mall crawler overnight.. Now I am into H3's because I like something different with new mods that are fun and yet again different that everyone else in their clone JK's. From all my rigs I'd say an H3 is like a Jeep/Rover mated which means the best of both worlds if you ask me.

I saw plenty of 231's and a few 241's end up looking just like what happened here. The worse one I saw was behind an RV, and the linkage went from N to 4L and exploded the transfer case so bad it exploded, blew a hole thru the floor, broke both drive shafts, cracked the entire case (more like peeled it open), and even destroyed the exhaust!!

The fluid going black so soon is just the fact it's an AWD setup and it's constantly having to work vs a Part Time system if you ask me. I'm pretty sure my wife's early 07 has the plastic shift fork because it's really quiet shifting from 4Hi to 4Hi Locked, and 4Low vs my 08 Alpha. Gonna go ahead and buy the metal shift fork and get ready to upgrade it one weekend.

Where you did Land Rovers, I did FJ40s - I had 7 of them (and one may be on its way into my fleet). I always avoided Jeeps because FJ40s were Jeeps after the mods (boxed frame, 1 ton axles, etc). With that said, I scattered FJ40 parts all over the place but their major issues were Birfield joints and the driveshaft bolts (two flat plates, bolted together in shear - so with a bit of vibration, they shear). I also had countless Chevy box-style pickups and an equal number of S-10 Blazers (I made money converting them to V8s). The S-10s... fortunately transfer cases and front differential were really, really cheap and easy to get...
 
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