Transfer Case broke....Replacing with Atlas
01-10-2010 | 09:24 AM
#11
JK Jedi Master
Joined: Feb 2008
Posts: 12,882
Likes: 172
From: Maine
They are stating to fail because most of the after market shafts dont reuse the factory dust covers or present a new one, therefore dirt is getting into the bearing and causing failure.
I have both front and rear after market shafts from two different companies and both did NOT come with replcement dust covers. I could not reuse the factory ones becuase they didnt fit. So it is just a matter of time before mine goes.
We are just starting to see the begining of a new problem that was overlooked with the instalation of after market driveshafts. Poor design from the aftermarket driveshaft makers becuase they wanted to get their product out on the street before the other guy.
I have both front and rear after market shafts from two different companies and both did NOT come with replcement dust covers. I could not reuse the factory ones becuase they didnt fit. So it is just a matter of time before mine goes.
We are just starting to see the begining of a new problem that was overlooked with the instalation of after market driveshafts. Poor design from the aftermarket driveshaft makers becuase they wanted to get their product out on the street before the other guy.
The pictures of the failed ones show a seal still on the shaft.
Any chance you could take a picture and post it? That would be a probable cause for sure.
Last edited by ronjenx; 01-10-2010 at 09:44 AM.
01-10-2010 | 09:28 AM
#12
JK Jedi Master
Joined: Oct 2006
Posts: 15,133
Likes: 0
From: O HI 4 Lo
i agree, people are grabbing at straws without really knowing th cause
01-10-2010 | 09:40 AM
#14
JK Jedi Master
Joined: Oct 2006
Posts: 15,133
Likes: 0
From: O HI 4 Lo
kinda like the front axles breaking, theres only been a couple
01-10-2010 | 10:56 AM
#15
JK-Forum Founder
Joined: Jul 2006
Posts: 36,534
Likes: 16
From: Laguna Niguel, CA
They are stating to fail because most of the after market shafts dont reuse the factory dust covers or present a new one, therefore dirt is getting into the bearing and causing failure.
I have both front and rear after market shafts from two different companies and both did NOT come with replcement dust covers. I could not reuse the factory ones becuase they didnt fit. So it is just a matter of time before mine goes.
We are just starting to see the begining of a new problem that was overlooked with the instalation of after market driveshafts. Poor design from the aftermarket driveshaft makers becuase they wanted to get their product out on the street before the other guy.
I have both front and rear after market shafts from two different companies and both did NOT come with replcement dust covers. I could not reuse the factory ones becuase they didnt fit. So it is just a matter of time before mine goes.
We are just starting to see the begining of a new problem that was overlooked with the instalation of after market driveshafts. Poor design from the aftermarket driveshaft makers becuase they wanted to get their product out on the street before the other guy.
so that it's clear, i have personally witnessed a t-case blow up and i got to examine the bearings after the fact - THEY WERE NOT SEIZED UP. i have also personally had a t-case start to crack and again, there was no sign of bearing failure. in every case that i have seen, t-case failuer has only been on JK's with aftermarket drive shafts and from what i can recall, all were running 5.13 gears. i should also point out that of the t-case i saw blow and on mine personally, the JK's in question were both suffering slight driveline vibrations at high speeds. if anything, the evidence point to this vibration being the cause of t-case failure.
Last edited by wayoflife; 01-10-2010 at 10:58 AM.
01-10-2010 | 12:04 PM
#16
JK Jedi Master
Joined: Feb 2008
Posts: 12,882
Likes: 172
From: Maine
so that it's clear, i have personally witnessed a t-case blow up and i got to examine the bearings after the fact - THEY WERE NOT SEIZED UP. i have also personally had a t-case start to crack and again, there was no sign of bearing failure. in every case that i have seen, t-case failuer has only been on JK's with aftermarket drive shafts and from what i can recall, all were running 5.13 gears. i should also point out that of the t-case i saw blow and on mine personally, the JK's in question were both suffering slight driveline vibrations at high speeds. if anything, the evidence point to this vibration being the cause of t-case failure.
The pictures have shown a drive shaft with a double cardan at the t-case. I assume the other end at the front axle has a single joint.
Is it common to all the failures that the front joint pinion angle is significantly more than "0"?
My advice for those with this setup, would be to not drive fast until this is figured out.
Speed seems to be the final ingredient (and the easiest to modify) just prior to the explosion.
Last edited by ronjenx; 01-10-2010 at 12:35 PM.
01-10-2010 | 04:26 PM
#17
JK Jedi Master
Joined: Aug 2007
Posts: 15,665
Likes: 3
From: Hammond Louisiana
This has been my gut feeling since I posted the "recipe for disaster".
The pictures have shown a drive shaft with a double cardan at the t-case. I assume the other end at the front axle has a single joint.
Is it common to all the failures that the front joint pinion angle is significantly more than "0"?
My advice for those with this setup, would be to not drive fast until this is figured out.
Speed seems to be the final ingredient (and the easiest to modify) just prior to the explosion.
The pictures have shown a drive shaft with a double cardan at the t-case. I assume the other end at the front axle has a single joint.
Is it common to all the failures that the front joint pinion angle is significantly more than "0"?
My advice for those with this setup, would be to not drive fast until this is figured out.
Speed seems to be the final ingredient (and the easiest to modify) just prior to the explosion.
Took it back to the gear guys , tore apart the TFcase and said it had to be the planetaries. Found another dealer that replaced the whole TF case , still the same noise, not as bad though. I ended up just pulling the front ds and sticking it back in for wheelin only. Got my 37's and installed TF springs, which are taller than what I had( angle even greater on ds) and the noise all but went away, barely here it at all. I think it's a gear/tire/ds /lift combo. Something goes on with that front bearing, at least it seems to me like a dry bearing sound, add the vibes to it and you got a recipe for disaster. When I had the 35's on the noise started at 40mph and was really loud at 70mph. Now it's barely audible at 70
01-10-2010 | 05:26 PM
#18
JK Freak
Joined: May 2007
Posts: 534
Likes: 2
From: Lake Oswego, Oregon
Personally, I wouldn't rule out the chain stretching from the additional stress of bigger tires and vibrating drivelines and then letting loose at high speed. In my experience back in my heavy wheeling days with Ford trucks and Broncos you would never see a failure like this with a NP205 as its a completely gear driven transfer case. I've OH them a couple of times and to tell you the truth they really didn't even need it and they were behind built 460's running 36 inch Ground Hawgs, Buckshot Mudders and Mickey Thompson MT's. The NP203 on the other hand... kaboom! and then they went in the scrap pile....
01-10-2010 | 05:49 PM
#19
JK Jedi Master
Joined: Aug 2007
Posts: 15,665
Likes: 3
From: Hammond Louisiana
Personally, I wouldn't rule out the chain stretching from the additional stress of bigger tires and vibrating drivelines and then letting loose at high speed. In my experience back in my heavy wheeling days with Ford trucks and Broncos you would never see a failure like this with a NP205 as its a completely gear driven transfer case. I've OH them a couple of times and to tell you the truth they really didn't even need it and they were behind built 460's running 36 inch Ground Hawgs, Buckshot Mudders and Mickey Thompson MT's. The NP203 on the other hand... kaboom! and then they went in the scrap pile....