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Unread 11-16-2011, 08:00 PM   #1
rat9
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Transfer Case and front drive shaft just exploded... why?

So I broke my rear drive shaft near calico. I'm not sure if the u-joint bound or I just came down to hard with too much gas, but anyway I tried to limp home on front wheel drive and suddenly huge pop and smashing sounds on the freeway. Engine cut out because the fuel pump was instantly ripped out. The transfer case has a huge hole in the front and the drive-shaft is bent and twisted. I do not remember tires screeching so i THINK the front diff is not at fault. I have 33 inch tires and had quite a bit of weight in the jeep but i was not flooring it, going above 50 or accelerating when this happened. I had been driving less than ten minutes. I have an extra wide chain in the transfer case and it was only two years old.

So i have opened the T-case and i do not see ANY gear or chain damage... just a ripped open case and ruined bearings, everything else looks perfect.

I will be checking the front diff in the next few days for damage.

My question is: Could it have been 100% the drive shaft just not being strong enough and have nothing to do with the transfer case locking up? I find it repugnant that a stock drive-shaft could be so under-engineered. I have a limited slip in the front.





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Unread 11-16-2011, 08:03 PM   #2
Xpress
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Look at the size of the front driveshaft compared to the rear. You can limp home on it but I wouldn't even dare try to drive it on the highways.
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Unread 11-16-2011, 08:45 PM   #3
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Your front driveshaft looks pretty skinny compared to mine. Looks like the OD of a CJ's. It's possible the driveshaft couldn't take the torque and began to deform and cause havoc on the driveline. I drove my jeep home in FWD through Atlanta on the interstate going 70 and I have a locker in the front. No issues.

Does everything spin in the shattered t-case? I assume the front wheels are not binding up either. I can post a pic of my stock front driveshaft if you'd like.
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Unread 11-16-2011, 09:35 PM   #4
oldtime_ironman
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That sure don't look like a stock front DS, and it doesn't look like it was ever balanced. That would have something to do with it I bet.

BTW mad propz for the most interesting damage I've seen in a while!
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Unread 11-16-2011, 09:39 PM   #5
Bojon
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Is it just me, or is there a pin wedged into the gear on that transfercase?
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Unread 11-17-2011, 02:15 AM   #6
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HI,
I'm interested in the outcome but have nothing to offer. Subscribed. I do think that with your 4:56 ratios, the drive shaft RPM's would be pretty high at highway speeds. As I remember, Jeep limits the 4wd speed to 40 MPH. And Jeep only offered 3:70 max. with the 258. Good luck.

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Unread 11-17-2011, 04:50 AM   #7
Jeepfan1
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Their is definatley something fishy about the size of that driveshaft. The D.S. is both of my YJs are are easily twice the diameter of that one
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Unread 11-17-2011, 04:59 AM   #8
oldtime_ironman
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Quote:
Originally Posted by Bojon View Post
Is it just me, or is there a pin wedged into the gear on that transfercase?
Looks to me like it was a roller from one of the bearings. My guess is the unbalanced front DS shook a bearing to pieces, and then all hell broke loose.
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Unread 11-17-2011, 05:13 AM   #9
roadyrob
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the driveshaft in my 87 looks the same, maybe they changed it in later years
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Unread 11-17-2011, 05:14 AM   #10
Louie4
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Just for kicks and giggles.

Here's my front driveshaft after it was straightened and balanced.





The more I look at it and think about it, the more I think the driveshaft is at fault. It looks like the driveshaft gave and something got in a bind.Then the weakest link in the t-case was the case itself.
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Unread 11-17-2011, 05:27 AM   #11
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Quote:
Originally Posted by Xpress
Look at the size of the front driveshaft compared to the rear. You can limp home on it but I wouldn't even dare try to drive it on the highways.
A stock front shaft is fine for this purpose.
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Unread 11-17-2011, 05:32 AM   #12
oldtime_ironman
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Quote:
Originally Posted by Poke View Post
A stock front shaft is fine for this purpose.
^^^^^ X 47. I've limped home before, about 20 miles one way at highway speeds. BUT that was with a proper setup, stock with balanced.
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Unread 11-17-2011, 05:35 AM   #13
Louie4
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Quote:
Originally Posted by oldtime_ironman View Post
^^^^^ X 47. I've limped home before, about 20 miles one way at highway speeds. BUT that was with a proper setup, stock with balanced.
.
Likewise. I had a 2.5 hour trip from the N. Georgia Mountains to Central Georgia, through ATL on Interstate 75. My rear locker took a dump and it would just spin and click but not turn the tires.
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Unread 11-17-2011, 05:56 AM   #14
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Quote:
Originally Posted by oldtime_ironman View Post
Looks to me like it was a roller from one of the bearings. My guess is the unbalanced front DS shook a bearing to pieces, and then all hell broke loose.
.
That was my first thoughts as well.Nice carnage.
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Any video of the sound?
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Unread 11-17-2011, 06:12 AM   #15
Louie4
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Quote:
Originally Posted by oldtime_ironman View Post
Looks to me like it was a roller from one of the bearings. My guess is the unbalanced front DS shook a bearing to pieces, and then all hell broke loose.
.
I like this idea as well. Makes the most sense.
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