What could cause this to happen?

[lepp1892]

I have broken the tailshaft housing off of my truck twice. The first time was about 5 months ago and now it happened again. The first time it happened it was kind of slow and cracked over time now this time it broke, it did it instantly, to the point where I heard it. I was missing one bolt where my t-case bolted to it so i don't know if that was a factor but it has been like that for at least a year and a half.

The truck is a 1992 Ranger with a 4.0 5 speed. I have a locked rear end and a couple of my friends think that is the cause but again that has been like that for a long time too.

Here are some pictures of the break.

Any input would be appreciated. Thanks

 

[LittleHorse]

are you running a non-stock transfer case?

Was the bolt missing for both tailshaft housings or just the second one?

Are you missing the t-case skidplate and have you bottomed out the truck on the transfer case?

 

[lepp1892]

It is a stock T-case.

Bolt was missing both times but the first time it happened it ran with it missing for almost a year with no issues and a lot more offroading/abuse the the second time it happened.

I do not have a t-case skid but the truck hasn't been offroad in probably 6 or 7 months so I wouldn't have bottomed it out on anything.

 

[Jspafford]

Is it the stock driveshafts?

That bolt may have been a factor in it finally failing, but I don't think it acted alone. There is some sort of pressure at work also. I would guess from a driveshaft.

 

[Zachalanche]

Could be a combination of missing t-case bolt and front driveshaft being too long when the suspension is compressed. I once saw an f350 crack a transmisison housing from the front drive line slamming into the transfer case during compression.

 

[LittleHorse]

That also sounds like a good idea, especially with your 6" lift there's a chance the driveshaft might be too long if it was lengthened along with the lift.

it's a shame I don't still have an extension housing lying around for you...but I sold it several months ago.

 

[lepp1892]

The rear driveshaft is a once piece out of a 99 ranger and the front is stock.

I guess I will get a new housing and find another t-case bolt and hope that was the main cause of the failure. Maybe I'll fix my manual t-case and put that back in and hopefully with that combination it will all work out...

 

[adsm08]

I have extra t-case bolts from my M5 swap. PM me with an address, I'll put one in an envelope, throw some stamps on it, and you can have it for free.

 

[Bent Bolt]

A few things to look for are front driveshaft slip joint seized or shaft to long. U-joint seized or very loose for a long time. Slip joint on rear driveshaft seized.

 

[PlumCrazy]

The output shaft on the trans could be bent causing the the tcase to "wiggle" around and eventually result in a crack that leads to a break.

 

[lepp1892]

ya i thought about that too... the output shaft seems tight and doesnt wiggle.

 

[Fx4wannabe01]

I've split the case in half and snapped the trans output shaft. Thank you locked ass, grabby clutch, traction bar, and a dumbass driving that clutch dropped it. Yay for toxic shock.