gmorgan

I have a 2007 jk and the transfer case just blow apart on the highway, I was in Niagra falls this weekend and on the way home at 60 mph. all this banging from under the jeep and oil all over the road and parts flying out. I pulled over to the side of the road as quick as I could and looked under the jeep and the transfer case was half gone and all the gears where hanging out still bolted to the front drive shaft I hade to be towed home 200 miles.
I still have no idea what happen, I have to call the dealer on monday this should be coverd by warranty I only have 28,000 miles on it I have warranty for 50,000 miles and 2 more years

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nthinuf

Lift? Bigger tires? Aftermarket driveshaft? Freeway speeds? Slightly less than an optimal pinion angle?

LynDi

These stories scare the crap outta me.

NH-JK

I hope they cover towing....

ronjenx

Yup. Recipe for disaster.

To add a little detail:
Lifted
Front drive shaft with double cardan joint at the T-case, and single u-joint at the pinion
Front pinion angle more than just a few degrees
Re-geared
Highway speed
Previously noticed vibration on the highway, but ignored it
Heard vibration briefly get a lot worse, then Ka-Boom

techd00d

Out of curiosity what did the noises sound like prior to the blow up?

I'm getting some minor vibration type sounds and feels around 3000 rpm in all gears 3rd and above, most noticeably in 5th.

ronjenx

Which of the items in post #5 above can you say yes to?

The problem with the t-case isn't engine rpm related. It's road speed.

Fenrir

How much lift we talking in your scenario? If I go with a 2" OME shocks/coils, would I be in danger of this issue? Or is this more of a 3"+ issue complicated by all the other factors you mention? Just curious.

ronjenx

It has to do with whatever causes the front pinion angle to be more than a very few degrees, when there is a double cardan at the t-case. That double cardan requires the pinion angle to be as close to zero as you can get it.

If you get drive line vibes that get worse at highway speeds, it's a time bomb.

KenB1010

I'm sorry to hear about this. I've been in the same place as well. Vibration in the front driveline seems to be causing the front half of the Tranfer case housing to crack. my front case half was cracked from the input shaft down to the bottom seam of the case. If caught early enough the front case half and the breather vent are the only parts needed to do the repair. if you don't notice the leaking oil then the case fails much like the OP's did.

I was able to find the crack after finding the puddle of oil under the jeep during a pit stop. when I did the repair the entire area around the bearings was spider webbed on the inside of the case.