I wish there were a better story here, and it's a comedy of errors, so hopefully you'll be amused,
I broke my front driveline at the output plate - and now my transfer case is in limbo.
Here are some facts:
- The yoke on the front driveline broke at the attach point to the transfer case output plate
- The break was caused by 2 missing bolts (and the third one lose it appears) and then going under load
- The transfer case was in 4L at the time
- The transmission was in reverse when it broke
- When the driveline broke, it rotated and gutted the transfer case wiring harness and other cosmetic underside damage (but I got lucky)
- Break occurred at rest; basically, the truck was under load but not in motion, and it wasn't a running yank
- Truck was on dirt
I'm sure you want to know more about the stupidity here, so a brief admission:
- I was pulling in reverse because I was too lazy to reposition; that was the first mistake
- I was pulling out a stump, which turned out to be less rotten and deeper than I thought, no reduction, wrong tool, mistake two (and three?)
- The missing bolts appear to have been missing for a while, and I felt vibration recently, kicking myself for not tracking that down four
Okay, so here is the current situation:
- Front driveline is removed
- Truck is still in low range
- Transfer case shift lever (manual) does not shift the transfer case. Has contact, the linkage is good, activates motors. Moves too easily.
- Hand turning the output flange, you can feel the chain turning (I think that is what I feel: light tension, clicking but smooth)
- Rear output is engaged, exercised F/R/N and different positions on transfer case lever (without front driveline attached)
- I put the wiring harness back together - think that went fine, but if anybody suspects electrical, this might be a revisit
- I have a new driveline, and 4 new bolts
So the transfer case feels like it's either garbage inside or just a bit confused.
Given that the driveline broke, I tend to think it didn't mulch the insides, and it's just between gears somehow, but before I tear into it, your thoughts, ideas, or jabs are welcome.
Attached are a couple of photos. If any video of the output shaft rotation (or sound) would help, let me know.
Thanks,
Wade
Bookmarks