Transfer case blowout
 

Hey Guys,

My transfer case blew out on the interstate and through the front driveshaft all over the place before it disconnected and did more damage to my trailer.

The damages to the truck include the:
transfer case
transmission adapter
front driveshaft
shift cable
rear brake line
Airdog fuel line
Airdog electrical lines
factory fuel lines
reverse camera
transmission cooler electrical
lift gate electrical
transmission sensors on driver side

I've pretty much gutted the underside of the truck removing all of the damaged components. I'm waiting on additional parts and should have this rebuilt in a couple of days.

I am going to replace the factory brake line with a steel braided line because of all of the turns and difficulty with hard lines.

I have a question in regards to the factory fuel lines. Since I am running an Airdog fuel separator/ pump, do I need the factory fuel lines? I am not sure if one is required for fuel return or not.

Your help is much appreciated.


https://cimg6.ibsrv.net/gimg/www.die...878f5ce729.jpg



Transfer case and lift gate wiring exposed.

https://cimg9.ibsrv.net/gimg/www.die...5334f920df.jpg

Electrical and fuel line tangled in front part of drive line.

Ouch! That hurts just to look at it.

Any idea what caused this? Have you been using your truck in 4WD very much? Heavy or light work? When this happened, were you in 4WD?

I seen a friends truck seize the CV joint, rip out of the transfer case and try to come through the floor at him, it really makes a mess when stuff like that happens, especially at highway speeds. As for your fuel lines, you still need the factory return line, but you can leave the factory delivery line out, I would just make sure it's sealed off.

I wish I knew. The transmission and front drive shaft were replaced 40,000 miles ago. So I don't think it was a lack of fluid in the transfer case. The yolk is still on the interstate somewhere north of Vegas.

Oh Man !! I might have just rolled her to the side of the road and shot her if I saw that under by truck . I feel for you .

Was there any indication before it grenaded ? Vibration etc ? ........ or just a bunch of banging until the rear yoke / driveshaft departed the truck ?

I feel like I need to go out and give my girl a nice wash and polish now so she will treat me nice.

DEW

Would make me start drinking again if I saw that under my truck.

Any Update
 

Was the fix successful? Any update? Pictures look like my truck.