hi

what make the transfer case flex and crack? Assuming there is enough good oil in it?

is it the gears to the rear diff?

 

In short, the case is too thin for the power of the engine. In first gear, the gearing is pretty low which allows the engine RPMs to be converted into torque. That torque is what is the twisting action and since the transfer case is changing direction of the rotation, it will put a lot of stress on the case, leading to the cracking that some have experienced. Once you get up in the gears, the torque issue isn't a concern.

 

I see. I was studying pictures of the tc internals and I was guessing where the moments and reaction points were. it seems that the gear on the lay shaft and diff output to the rear is being pushed apart and the case is not strong enough to handle that reaction.

Maybe a case machined from billet aluminium or maybe steel would allow the transfer case to store more oil and handle more torque? Like a turbo 3.0?

 

Is there any companies do rebuild and reinforce to make the TC stronger to take more power?

 

none that I know of. I'm thinking even mild steel would make a strong case. Could even be welded together.

 

Since we know exactly what could happen, if it does happen -

1.) what's the typical hardware cost to replace/repair the TC, and

2.) is there a best practice write up on this anywhere? For instance, buy so and so particular TC parts, and while you're in there you might as well do so and so, etc?

I read a ton of threads on this but don't think I've seen it pulled together.

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