I changed out a tcase on a 2001 Excursion recently with the same result. These cases are no stranger to grenading from pump failure. There was plenty of ATF in it when it locked up. It covered the bottom of the truck and had quite a large puddle of fluid under it when I towed it.

 

Interesting that so many failure stories are surfacing - still, it must be an uncommon failure. If the pump failed and they could substantiate it, I would still want to know what caused the pump to fail (realistically, I realize that there would be little hope of actually getting an answer to that question though, but still ........).

 

This actually was the second one in two different trucks in the past year. The only thing holding the halves together was the chain.




Blown case

 

I usually lock my hubs at the first snow and they stay locked till spring.


ESOF does not work well in the colder temps.

 

Interestingly, it looks like both transfer cases failed at the same spot. I wonder if that's due to what failed internally, or if that point is just the path of least resistance?

 

What a conundrum. Dad said there was fluid, alot of fluid on the ground once he got pulled over but he couldn't tell where it was coming from as he cannot get that low to see. After the 50 mile tow to the dealer and a few hours later is when I took the pictures, there was fluid that showered the whole underside as well as the back of his tailgate and new shell. I asked the dealer to get someone to at least wash the back of it to get the fluid off the paint.
The coming apart happened at 80 mph which is probably why we aren't seeing fluid in my pics.

Those of you that have been driving with your hubs engaged.....isn't this during the winter months? Any 80-90 mph long stretches? Not doubting what is being said at all, just comparing differences. He left the Phoenix area and when he got into the Palm Springs area it was in the mid 90's.

Does the fluid pump in the tc run when not in 4w? Hearing the same tc is in the Dodge with full time hubs makes me wonder about the pump in those too.

 

The pump is around and driven off of the main output shaft. In my picture you can see the black suction hose that is normally attached to a strainer pickup in the lower corner near the drain plug.

 

So it's a mechanical pump and will be pumping as long as the case is being driven by the trans.

Could be: (feel free to add to the list)
1. tc pump failure
2. not enough fluid to the overheated parts at front of tc @ high speeds.
3. rear u joint on front drive shaft failure
4. any combination of the above

 

Presumably it will always crack there: when it seizes the casing will start to rotate but the front driveshaft will pull it forward at an increasing angle. If the front bearing seizes the reverse will happen. Lots of energy with nowhere to go.
I'll still be doing a Senix this winter though.

 

Mark you PM box is full.



Sean

 

for the record the one that blew apart on the truck i purchased was a 99 sdf250 ext cab shortbox with a 5.4 engine and auto trans.

 

This is what mine looked like fluid everywhere underneath the truck all the way up the tailgate and it was up so running 85mph when mine blew and the spray went everywhere held on and when I stopped the smoke was horrible but when all was good I drove it another 1,000 ft to get to a safe spot on the highway.


Notice half the case gone

Notice chain hanging out but still intact

 

I have a 2003 V10 Excursion sitting in front of my house that belongs to a buddy of mine. He was driving his home from church when the T-case blew.


03 V10 Excursion
I just found this post around 3 am, so I will check and see if the hubs are locked in the morning. It was towed directly to my house from where it blew. I have a shop and a lift and were going to replace the t-case, but I was researching what may have caused this and discoverd this thread.
It still drives like this, but it also damaged the fuel line and that is leaking heavily right now when fuel pump is on. He was driving highway speeds when it occured.

 

Thanks for going to do that. It would help with the puzzle.

 

So I can't tell if they are locked, they are not labled. Which way is locked on these? Clockwise or counter clockwise.