I had a transfer case go out on my 06 2500 and bought a new one from Transfer Case Express in SC...Had it installed just 2 months ago. Now, I have a 2 inch crack in the transfer case! It has a one year warranty...I called TCE and they said Dodges are having a big problem with this b/c of U Joints or Yolks or something like that...was really giving me a hard time about the crack and asking me all kinds of questions...the truck is stock, does not go off road, and only has about 1500 miles on it since I the new T case put in. He said its not a defective transfer case but something defective in the drive train that is causing the crack, and if he sent me another one, the same thing would happen again. NEED HELP FAST so I can make an educated argument back....

 

Was your first transfer case cracked?

 

The one that went bad was not cracked...had a chain break on the inside...this one is cracked after 2 months

 

Were did it break, castings can have flaws, see it all the time at work.

 

From my perspective, there is your answer, your truck had no issues that would split a transfer case prior to putting in a rebuilt unit.

I would say this case was stressed from the truck that they got the case from, either in a wreck or that truck had a Ujoint problem........

 

I've run into this scenario at work at least five times, however I have NOT seen a transfer case crack, but rather the OD housing where it mates to the rear of the trans. Not saying it couldn't, but reflecting experiences that I've encountered personally.

 

I Agree!!

 

I keep trying to post a reply with pictures, but it keeps giving me something about "invalid user session"...ill see if this goes thru...

 

If you had a seized U joint to the point where it caused a huge low speed vibration, and you ignored it for many miles, I could see that stressing the t-case, but if not I'd call them on it.

To me it should be up to them to show some evidence that the tc cracked because of some other problem, rather than them just assuming that and claiming no warranty.

I guess if I were in your shoes, I'd offer to let them pay for a mechanic to examine the truck, and if the mechanic can show you what is wrong with your truck that caused the crack, fine, but if not they owe you a warranty replacement.

I'd probably insist on the mechanic being from a certified Dodge shop, who would have no horse in the race and no bias.

 

OK...here's the final analysis...It WAS NOT a cracked rear housing on my T Case...it was just where the casting seam was stamped. Turns out it is a yolk/UJoint/seal/etc problem...it was only 100 bucks more to just order a new drive shaft with parts, so I am just having new drive shaft put in. I was pretty sure that was not a crack...and its confirmed now. Hope this will clear it all up now. I wanted to post pics of the problem and the "crack" so everyone could see and for folks benefit if someone else sees something like this...but I cant get this site to allow me to post attachments. Not sure what I am doing wrong. Appreciate everyone's help and advice.

 

To post attachments just use the manage attachment button below.

Perhaps your attachments were to large? I know many of mine I have to run thru a program like Xsqueeze me to compress to below the 500K mark or 1024x1024 for .Jpg