BLOWN t-case

[b411sac]

So I got the t-case out, took 5 minutes. The transmission extension housing thouroghly grenaded, But the t-case appears to be fine, as does the tranny. the U-joints in the read d/s are SHOT and the cv joint for the front just slid apart (idk how this is fixed need some help with that one) so all in all the damage seems managable, for now.
here's a link to my photobucket album with all of the pics i took, to many to post on here.
http://s914.photobucket.com/albums/ac348/b411sac/ford/

 

[aspevacek]

Lookin gat the pics on th ephoto bucket, the redish colored rust powder in there would indicate that the output shaft from the Tranny was vibrating inside the Transfercase input shaft. I would check the interface fit between those 2. I am pretty sure if the U-joints had enough wear on them and they were allowe dot vibrate at highway speed they could cause enough harmonics to vibrate the entire transfercase. That would load up and cause stress fractures in the weak link which in your case was the transmission extension housing.

 

[Snoranger]

I wouldnt worry in the least about the little bit of rust dust. I've pulled at least 50 of these cases and the only ones that didnt have that light dusting were VERY low mile manuals or most autos (they dont have a rear trans seal, the extension housing holds some fluid.)

 

[bigbadford91]

Did you take the u joint cap out of the rear drive-shaft? If you just changed the u joint and then the transfer case failed, I would say the two are related. The u joint cap probably fell out and then put the drive line in a bind and broke the weak link. Lots of leverage when your hauling down the highway.

 

[b411sac]

One bearing cap from each ujoint on the drive shaft was gone when I pulled the t case, there's no way to know what happend first, caps coming out or tail housing failure, but they are certainly related.

Sent from my moms car while mine is waiting.