Originally Posted by 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.

Originally Posted by gmorgan

I have a 2007 jk and the transfer case just blow apart

Originally Posted by jlarso

What would front pinion angle have to do with a Tcase gernading on the highway?
If it was in 4WD I could see it and the answer is obvious, but I doubt very much he was in 4WD.
Just curious

Thanks

Originally Posted by 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.

Originally Posted by Alaska-HWY JK

This is confusing (the pinion at 0 degrees). You want the pinion pointed towards the transfer case. A stock axle has 6 degrees angular separation between caster axis and pinion, my PR 44 has 10. I run 6.25 degrees caster and 3.75 degrees pointed up towards the transfer case. What you mean is as little angle as posible between pinion and driveshaft angle isn't it? With still enough caster that you don't wander all over the road.