Did my transfer case just explode? Please help!

Hello everyone,

I just regeared my tuck last week to 5.29's last week and finished the break in period for the rear gears a few days ago.

Tonight I was going out to grab dinner and figured it would probably be a good idea to put a few miles at a a time on the front gears to help break them in also (I've already been doing this a couple of miles here and there this week.)

Tonight I did this and my truck came to a screeching halt and scared the crap out of me. I was at a stop light engaged 4wd and started driving when the light turned green. Luckily no one was behind me and I was in a light traffic area. I was not going fast, maybe 30 mph, by the time the truck made a horrific sound and came to a stop.

I was stuck couldn't move, the engine was still running but I was dead in the water. I put my hazards on and tried to gain my senses back and figure out what the hell just happened. I was able to eventually able to get it out of 4wd (but with a loud bang) by giving it a little gas. I drove to the parking lot next to me and it seemed fine in 2wd. I tried reengaging 4wd, same situation as before, truck was stuck in place and hard to disengage 4wd.

I drove home in 2wd (obviously) and everything else seems fine so far. Shifts fine, drives fine. I looked underneath and there is oil splatter every where all over underneath past the transfer case.

I have no idea what to do now. I'm going to call the shop I did my regear at tomorrrow because that's my first most likely culprit. The thing I'm now worried about is obviously the front diff, but also the transfer case, and possibly transmission? I can't tell where exactly the transfer case is leaking from in the dark or if it's a steady leak. I'll climb under there tomorrow to see if it's still leaking and from where.

What all do you guys think I need to worry about at this point. For all I know I could have just grenaded the front diff, possibly the transfer case, and maybe even hurt the transmission for all I know. I feel sick right now thinking the potential cost and time to fix these.

Any input will be appreciated. Thanks.

 

Shit luck, sorry to hear. Did you supply the parts or did they? Hopefully they fix it and don't put the blame on you.

Best wishes.

 

They supplied parts. But at this point I’m not just worried about the diff, I’m worried about my transfer case too

 

the loud bangs almost certainly are gears. Recently bombed my rear and needed to move it out of the way. Each bang is a tooth snapping off. The fluid is interesting. Are you missing any bolts for the fill anywhere? Also does it smell like gear oil? You will know as that stuff is potent.

 

Yeah looks like a blown case to me. Guessing of course. But in terms of the shop fixing it, I hope they do the right thing. Although I wouldn't be surprised if they try to blame you

 

I have not felt around the case it’s dark and I didn’t wanna get covered in oil. I will check tomorrow

 

Hmmn... Shortly after I got my gears replaced, I had fluid under my truck just like you do. I never actuated 4WD though, so it was easy to determine the leak was from a bad transfer case seal. I'm no expert, but I wonder if you had that leak before hearing the bang. Just something to consider, anyone can feel free to correct me if I'm pushing Op in the wrong direction though.

 

Give them the opportunity to fix it...when they blame you file a claim with their liability carrier.

 

Daaang. Reminds me of when I was 19 I was a jeeper and came down hard on my left front axle. Bent my front spring and front drive shaft. The impact actually cracked the case of my transfer case. Being 19 and working for my dad it took me 6 months to save enough money to buy a new case half, replace the front shaft, and leaf spring. Then another 3 months to transfer the internals. I actually rebuilt it 2 times as I forgot a couple c clips in there, lol. What an experience!
The good news is ur prob not 19 and can claim it on ur insur if it naded and the gear shop doesn't take responsibility.

 

I can positively guarantee it was there because of this event. I’ve been crawling all around underneath my truck putting on my lift this past month. I would have definitely seen this much oil, and it’s fresh as can be, like it just got there.

 

sounds like maybe mis-matched front/rear diff ratios putting a bind in the drivetrain

 

Nitro gears? They recently had a batch of 5.29s that were accidentally sent out as normal gears but were actually reverse cut. My local shop had 2 sets in their inventory. May or may not cause the T case issue. Could also have had 5.29 installed in one and 4.88 installed in the other. Good luck!

 

Well I’ve been driving it a couple miles here and there in 4wd trying to break it in. It’s been fine up until tonight. I feel like mismatched gears would have had problems right away.

 

Since you've been running it in 4wd earlier in the week, that doesn't sound like a mismatch to me. Sounds to me like something broke in the front diff.

 

Well that changes everything. Definitely not your typical mismatched gear issue.

 

Also quick question, if everything is fine in 2wd do you guys think my transfer case is okay and it’s just the gears in the diff?

 

It's good that you were inspecting. Unknown variables like that make finding the actual cause, or who is at fault, difficult.

Hopefully the place that installed them will make the repairs for free - assuming you still trust them after this.

I find it interesting that the issue didn't exist until later on. That's a good data point for others who know more than I to help with.

 

Could be as simple as a forgotten bolt backing out. Sucks.