Hi all, I know this is a Dodge Forum but I trust all your advice and thought I would ask here first.

A friend of mine has a '99 F250 Extended Cab, 4x4 (Electric shift with Manual Hubs) auto tranny, 5.4 Gasser.

She has been complaining about noise and vibration when driving and then just the other day a "Clunking" under accleration.

So I crawled under it the other day to discover that the cast iron section between the tranny and they transfer case is busted!

I'm not 100% sure what this part is, I only had a quick look and obviously saw what the porblem was in about 30 seconds, I think it is a coupler of sorts between the tail shaft of the auto tranny and the input shaft of the transfer case. Not sure if this is actually a part of either the tranny or
t-case.

She is a young single girl on a tight budget, 2500 miles from her family so it looks like I will be fixing it for her in my garage. I'm not a 4x4 guru by any stretch but I did replace the Manual Tranny and t-case in my '99 Dodge last year and it doesn't look that tough to get apart, (besides all the corrosion!)

Does anybody have any experience with these trucks or know anything about it??? I had a quick look in a Haynes manual but it didn't seem to show where the tranny and t-case splits or really have much usefull info at all, the Haynes for my '99 Dodge is much better.

Any help would be appreciated.

Thank you.

 

Is she pretty?? Young single on a tight budget... (Just kidding!!!)

About the transfer case- I don't know if it's the same as with the F150 I did, the part you describe soundls like a tailshaft housing that is an adapter to the transfer case. (Sorry can't describe it any better)
On the 150 there were just some bolts to fasten the transfer case to this part and the drive shafts and the transfer case came out. I saw this broken tailshaft housing and there was a lot of carnage inside the tranny. (Don't know if this was a result of the broken case or the reason for it. )
If you have it apart check for runout on the output shaft, it could be bent.

HTH

AlpineRAM

 

Yeah I would say that is what that part is Alpine, a tailshat adapter of some kind. I'm not sure if the Carnage is in the Tranny or not, I was expecting more along the lines of a piled up T-Case that maybe the chain jumped or something and torques stuff enough to break that adapter??? Not sure. The truck still drives, (Although I told her she can't drive it anymore, I'm giving her a ride to work until it's fixed) it does shift a little bit harsh on the 1-2 shift.

Not sure I can see the Tranny breaking that part, it is directly behind the Crossmember and Transmission mount. The T-Case is bolted to it and then the driveshaft off the back of the case, the slip joint is at the rear of the driveshaft, just forward of the diff end u-joint.

This is why I was thinking that either the slip joint bound up and torqued that adapter to the point where it broke or the T-Case bound and twisted it till it broke, speculation at this point I guess.

 

I think the F150 is a bit different then.

I hope it's nothing major and that you can find the parts in a junkyard to get it fixed for cheap.

Best wishes!

AlpineRAM

 

My son has an F250 1999 (powerjoke), but the transfer case will unbolt fairly easy from the tranny. The bigger obstacle will be getting the crossmember off. Pretty straight forward job.

 

Right, I don't think you need to take the crossmember out to remove the T-Case

I'm more wondering what is involved in that extension housing, p.s it costs about $370. and what might break it? I'm thinking either the t-case is piled up or the slip joint is binding causing the driveshaft to pry on the tcase.

Lots of fun.

 

Yep, you don't have to remove the Crossmember to pull the tcase but you do have to remove it to get that extension housing off. <sigh>

It appears to me as though the two u-joints on the tase end of the drive shaft are fubard and binding which perhaps caused the vibration and the xtension housing to crack.

The new extension housing that Ford gave me has a hole in it for a speed sensor I belive, this truck has no sense speed sensor.

Think it's ok to plug the hole with something and install?

what should I look at as far as the tranny and t-case goes, while it is apart??

Thanks for the help.

 

For those interested in the Ford saga:

On closer inspection, not only were the u-joints messed on the drive shaft (front and rear shafts) but the cv joint between them (on the tcase end) was shot as well.

So, had a new driveshaft made at a driveline shop (it had bent the tube some too) Since the correct xtension housing was weeks away I plugged the hole in the xtension housing with a rubber plug and RTV, installed, reinstalled tcase and new rear shaft and she is back on the road without a front shaft for now.

Put a couple hundred miles on the truck this weekend and it is working good.