2003 3.4l Transfer Case Failure

Anyone ever heard of the transfer case failing and taking out the drive shaft? My friend had a 2003 3.4l AT extra cab TRD which he sold to his nephew. When I asked him how the truck was doing, he said his nephew blew it up. His nephew, who is an auto mechanic (specializing in Toyota, but not at a dealership) is now looking for salvage parts, which are running almost to 4K.

Just wondering what others may have experienced with this kind of problem.

 

Depends on how hard he was being on it and how often it was serviced. It is a chain drive transfer case which isn't the strongest to start with, and if it was under maintained, abused while crawling or on pavement, failure is very possible

 

Truck was a commuter/daily driver for original owner most of the time since new. Local mechanic did most work after warranty, but it did not need much. Well over 200K, mostly highway miles, never off-roaded. Don't know about his nephew.

Original owner bought a 2016 TRD sport last summer.

 

I'd ask the nephew if he was playing with it or running 4wd on the pavement. And many mechanics will only fix what you tell then to fix. It's kind of the owners responsibility to know what maintenance needs to be done. I wrench for a living and I can't keep track of what maintenance has or hasnt been done on the 100+ trucks I work on every month. If that tcase oil never got changed it could have been pretty ugly

 

I sold a front diff, auto Tranny + transfer case to a guy. His story was, the PO let the front diff fluid get too low. Soon after it changed hands the diff grenaded, taking with it the Tranny and TC.
Not sure if any of that was true. Just the story I was told...

 

"It is a chain drive transfer case which isn't the strongest to start with..."

Uhh......

 

If it's being used for, let's say rock crawling, chain drives aren't that strong. Gear drives are much stronger. That's why many switch out to an atlas or inchworm

Don't get me wrong, for a stock truck that TC is very capable. Anyone who has pulled one knows they are heavy and IMO overbuilt for a stock truck. But if it's being modified or abused, a chain drive TC can only take so much...

Unless I'm misinformed and the stock TC isnt chain drive

 

You are correct.

 

I'm going to take a guess and say that young nephew was using his truck like all young lads do, and beating the living piss out of it off-road. And in doing so the transfer case blew up, like any part can when abused.

 

Destroying that chain drive is no easy feat.

Improper care is always a factor, but that tcase is pretty robust with the factory driveline.

Just saying to continue looking to see if other factors contributed. I feel like that front diff or cv axle would let go way before the tcase would.

 

Should be getting those parts from a junkyard or ebay/craigslist for way cheaper than 4k.

 

My two possible scenarios were pavement or contact.

If I'm not mistaken, if operating 4wd on pavement, the stress goes directly to the drivelines and tcase, not necessarily the axles. But yes, the front diff should definitely be checked. Maybe that's why hes looking at 4k to fix it?

Contact: Did he just smack the TC too hard on something he didn't have the clearance for and literally break it?

 

I have a little more info on the situation.

Toyota told the original owner that the transfer case was leaking. Gave him an estimate to fix $$$$. He said "How much for one of those shinny new TRDs over there?" Sold. They would have allowed him $3,500 on a trade, but being the kind and generous uncle that he is, he sold it to his nephew for about that same price. So, nephew knew it needed transfer case work. In the mean time, nephew lost his position at the shop, deferred the maintenance, and we speculate that the case went dry.

So there you have it. Don't defer maintenance, and definitely don't let your TC go dry.

I don't think he has the money right now for even salvage parts.

 

Sorry to hear about the misfortune

 

Maybe he installed tires that were different sizes and blew it up that way

 

A good reminder for me to keep an eye on my weeping rear t case seal...or fix it.

 

I was thinking low fluid. That confirms it

 

Mine too. Mine sweats. No drops, but enough that the rear of the case constantly looks greasy