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Transfer case just exploded on the freeway

14640 Views 53 Replies 22 Participants Last post by  Gator1, 
totalled07
2
So. I have a new to me 2007 2500 4x4 with the 5.9 and 48Re. I was just on the freeway (20 minutes ago) and cruising at 70 when the vehicle started vibrating noticeably (not bad, but made me question if it was the road or the vehicle) so I slowed to 60 and it seemed to get worse. As I was pulling onto the shoulder it started shuddering and at around 30 MPH I heard the big clatter. Transfer case spilled its guts all over the road. 80% of the case is gone.

I forgot to ask my question:Is there a separate fluid circuit for the transfer case, or is it tied to the transmission. Also,if I pull the guts and the front driveshaft can I limp around in 2WD while I track down parts?
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Danderson
Tom Woods will build you a better quality front driveshaft.
4xshaft.com

Dodge 2500 and 3500 Front

Dodge Ram Front Drive Shaft Fits all Dodge 2500 and 3500 trucks that use a flat flange at the transfer case and a serrated (grooved) flange at the axle. If you do not have a serrated flange at the differential this will not work on your vehicle, you will need to call us to order instead. Double...
4xshaft.com
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rayvin433
I wonder what Tom Woods does with the POS CV joint. That tiny little aligning pin & ball receiver is definitely the weak link in the stock shaft. Once that alignment pin breaks it’s all over especially at highway speeds.
On a non lifted truck, I don’t even know why they need a CV joint. The angles aren’t that extreme. I’m sure glad I have a free spin kit. Saved my butt a few times when the CV joint started to fail.
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panteragstk
I need to remove my front shaft until I can order one from Tom. I really don't want to risk this happening.
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9412valvecummins
The same thing happend to my friend in idaho. He has a 2003 third gen with the manual shift transfer case. It jumped into 4wd while the automatic was shifting into overdrive going 50-60 miles a hour. Exploded the transfercase and put a hole in the transmission bell housing. Dropped a driveshaft on the freeway which hit a car behind him. Huge expensive mess.

I believe there was a recall for these trucks because the transfercase was too easy to shift causing these problems.
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Gator1
Also I hate to burst your bubble, but for the guys with a 68RFE trans they're the most problematic because they were literally designed for a front wheel drive mini van, and when they ran out of 48's for the trucks they started putting the 68's in the trucks. Nice...
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Gator1
9412valvecummins said:
The same thing happend to my friend in idaho. He has a 2003 third gen with the manual shift transfer case. It jumped into 4wd while the automatic was shifting into overdrive going 50-60 miles a hour. Exploded the transfercase and put a hole in the transmission bell housing. Dropped a driveshaft on the freeway which hit a car behind him. Huge expensive mess.

I believe there was a recall for these trucks because the transfercase was too easy to shift causing these problems.
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That may be the story he told you, but I doubt it lol. I have an 03, and that's just not very likely...A more likely scenario was he tried shifting on purpose at the wrong time and grenaded it, that they will do.
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panteragstk
Gator1 said:
That may be the story he told you, but I doubt it lol. I have an 03, and that's just not very likely...A more likely scenario was he tried shifting on purpose at the wrong time and grenaded it, that they will do.
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I was about to say...

My T-case shifter is on the floor where any other manual shifter should be. If I don't touch it, it doesn't shift. Easy isn't a word I'd use to describe shifting from 2-hi to anything else. Mine takes a bit of effort. I don't see how it could be done on accident unless someone was doing something else they probably shouldn't be doing.
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rayvin433
My 273 once shifted on my own. Unfortunately it was with the free spin hubs unlocked at highway speeds. It only happened for a split second but made a nasty noise trying to engage without the front shaft spinning. Had to rebuild the transfer case after that mishap.
If the hubs were locked or in factory form, it would not know the difference since shaft speed is the same front to rear
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5.7 Hemi
I heard the 68 was developed due to the Cummins. So how exactly would that big trans fit turned sideways for a front wheel drive application?
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Gator1
uh I don't believe that BS.... people will try to cover their stupidity with all kinds of excuses.
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Gator1
I do remember replacing the shift linkage on my TC a while back the shift lever was moving all over the place and that worried me. It just needed new rubber vibration isolators and good to go. If you're worried, or see it slopping around you may want to crawl under and inspect it.
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9412valvecummins
Gator1 said:
That may be the story he told you, but I doubt it lol. I have an 03, and that's just not very likely...A more likely scenario was he tried shifting on purpose at the wrong time and grenaded it, that they will do.
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I find that highly unlikely, his truck makes 600 horsepower on the highest tune and possibly the poor transfer case couldn’t take it all. The transfer case was very easy to shift according to him.
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panteragstk
9412valvecummins said:
I find that highly unlikely, his truck makes 600 horsepower on the highest tune and possibly the poor transfer case couldn’t take it all. The transfer case was very easy to shift according to him.
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Might have been loose linkage like @Gator1 said above. They sell beefed up linkage for anyone that wants it. I'm considering it just in case.
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Gator1
Best story I ever heard was my brother trying to explain how he was just driving along and his $11000.00 race trans blew up, and sent a gear flying through the air. Turns out what really happened was he blew a shift, over revved it, and then slammed it into gear, and KABOOOM!!! Like I said, we all have our stories, the ones we tell our selves, the one's we tell our friends, and the one's we tell the police.🤣
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