Here is a good one guys. We were on the road early this morning on the way to a job with one of our grain reclaim machines and the transfer case in my pickup pert ner exploded. It was just going down the road in 2wd at 70mph pulling around 6000lbs and with no warning there was a terrible bang and tranny fluid all over the road and my buddy driving the truck pulled over and called me to say that I needed to turn the Peterbilt around to come see this. The front drive shaft cv joint was broke right in the middle, most of the front output side of the case was gone, the one side of the chain was on the skid plate and the other was still around the gear. The rear output part of the case along with the shafts is still all together. Then to top it off, part of something bounced off the front of the trailer and caught to top corner of the left taillight lense, breaking it and putting a small hole in the boxside. So anyways, what do you think caused this?

 

One of about 10,000 causes could be that the front driveshaft broke or somehow disconnected, jammed into the road and drove itself into the case.

 

The driveshaft is still connected to the front axle and was rebuilt less than 1000 miles ago.

 

Post some picture's of the carniage maybe we can figure out what broke first.

 

there is a oil pump in there that has a stainless steel tube on it
, the setup does not lube very good in 4wd one of two things happened if you have a kit on to disengage the front axle and have the shifter in 4hi this will do it or the pump or tube failed and the results are the same all that fail look exactly like that now the bad part enough of them have failed this way that there is a shortage of cores a new one is about 3,200 installed by a non dodge dealer with no core a rebuilt will cost about 2800

 

I can buy a rebuilt one without a core for 1250.

 

Could have been a bearing siezed up? Or else something ran through the gear mesh internally creating a bending failure (tooth loss) on one of more of the gears? Personally, hearing that the front axle (I'm assuming - or the driveshaft) was rebuilt 1000 miles ago raises suspiscions with me in terms of something not going back in right, or a slight misalignment issue with the driveshaft. I know, more questions than answers, but I'll be interested to know what you find out, I work with failure analysis somewhat and these are questions we must ask. I would at least contact the shop that performed the last repair and see if they suspect anything.

 

where did you get the 1250 rebuild

 

in the t case in my bronco
i had a bearing come a part and busted the tail shaft
maybe some in the same order could of happened just not in the tail shaft

 

The snap ring in the back of the t case is also a known fault, I had one go and it was not good.

 

The $1250 transfer case is from a local parts store and has a 12 month 12k mile warrenty. I have put one in an older truck that we plow snow with and haven't had any problems yet.

 

Getting a new one from Dodge, $1525. Driveshaft is only $340.

 

I was in 2wd with the grand cherokee (which is also a New Process case) when my t case let go. The chain was stretched. I had pulled a heavy load of wood out of the wood swith it and probably stretched the chain. It started ta make a big bang, I guess skipping off the gear occasionally, then let go. Sounds like yours may have been stretched, finally bound up, and let go. Another problem when it gets stretched some, is ther is a plastic pick up tube (at least on the NP242) that runs under the chain. The chain sags enuff to wear through it and it loses flow and runs hot.

 

im in this thread a little late,,,whatd u find out,,,same thing happened to me,,,front line broke,,,slapped a hole in the oil pan,,,dissenigrated the transfer case,,,bent the rear driveline and blew the skid plate off,,,did the chain freewheel off the tranny or no,,,just curious,,,it cost me $4755