Re: Anyone else break their transfer case?
 

As long as they had this issue fixed by the time mine was built :D

Re: Anyone else break their transfer case?
 

Good thing you waited so long, huh? ;)

Re: Anyone else break their transfer case?
 

LOL As they say, good things come to those who wait :D

Re: Anyone else break their transfer case?
 

Makes sense, but won't excessive backlash put more strain on the gear teeth? Not an expert in gears, unless they have electricity running through them.:D

Re: Anyone else break their transfer case?
 

Technically yes, but it would make noise, and alot of it, long before it would sharpen the teeth to the point of fracture. Normal backlash is .005-.009", someone posted here that their's were measured at .022" with the lapping compound issue. But that brings an interesting variable as excessive backlash could break teeth under a heavy shock load, maybe I need to re-think my position. :confused:

Re: Anyone else break their transfer case?
 

That was me, the tech at the Moab 4x4 outpost is the person who said my backlash was .022. He even said that was a huge issue regarding the failure.

Someone then asked how could he know that, another expert said he could have simply turned the gear to measure.

Lapping compound was not an issue in my case.

Re: Anyone else break their transfer case?
 

You probably know more than I do in regard to this area; but I'm learning fast.

As for Bebe's her failure was not due to excessive backlash or lapping compound. The only real lapping compound problems I have heard of are the early rear axles, and not all were affected. And, as you state, the noise gets people in at around 3-4K.

Re: Anyone else break their transfer case?
 

Just curious do all of the failed front diffs. have the off-road package with the 4:1 T-Case?

:( This is starting to look like a housing flex problem. What happens is that the differential gear teeth are tapered and they try to spread the diff. case apart when subjected to a high torque load. When the case spreads the teeth are no longer in proper mesh at that point (the teeth make a high flank contact similar to being setup with excessive backlash). A high flank contact severly loads the tooth on the ring gear and causes it to break away from the base of the ring gear. The measured .022" backlash would be indicative of a housing that was severly loaded enough to stretch the housing beyond it's elastic limit. The housing was sprung and never returned to it's original shape ( similar to overspreading a Dana housing too far when installing a gearset. A housing can be easily ruined if somebody gets carried away with the case spreader as they should never be spread more than a few thousands of an inch to facilitate getting the carrier and bearings back into the housing).

BTW- the tech that actually took time to do "failure analysis" and measure the backlash before removing the gearset is a pretty good tech. Most would never have bothered to take the time to check.;)

Re: Anyone else break their transfer case?
 

For what it's worth, mine does not have the adventure package.

Re: Anyone else break their transfer case?
 

Interesting you bring this up, as case deflection is something I mentioned in my post in the other thread about the front diff grenading. I hope you are wrong otherwise we're going to see lots of these...

Re: Anyone else break their transfer case?
 

I think you (and rckrawl) are definitely on to something.....!

Questions:

If the flex causes the pinion gear to shear off ring gear teeth, then this would occur under extreme "Flex" conditions? With IFS???

If the case has been flexed, ring gear damaged, is the housing still useable???

Should I have the differential housing inspected? Replaced?

Would a housing made from a different material (H3's are aluminum) be more stable?

Is there any manufacturers who produce a Cast iron or some other type of Steel housing?

Regarding the tech, he was exceptional. The entire Crew at Moab 4x4 Outpost is exceptional.

Thanks!!!!

Bebe

Re: Anyone else break their transfer case?
 

thats what they did for me i have a nice shiney completely new front diff :D

Re: Anyone else break their transfer case?
 

:mad::mad::mad::mad:

I should have called Hummer like you did. Next time, slap me if I don't...K?

Re: Anyone else break their transfer case?
 

i might pinch you on the bottom , but I would never slap you :p well , i guess i could slap you on the bottom ;) :D

Re: Anyone else break their transfer case?
 

i should hope so Mr. Banzai driver ;) :D

Re: Anyone else break their transfer case?
 

No....It's BAM BAM :D;)

Re: Anyone else break their transfer case?
 

Seriously though,

If this is the issue, I can see not having a recall, but for as much wheeling as I do, I want the fix....before it breaks again.

5 extra days in Moab, well it was fun, but I do not want to do it again.:mad: