It happened to me the same thing this weekend.

 

ouch. What year was the truck? Now I'm starting to get worried about my decision to buy a SD.

 

I've noticed when I drive in 2wd with the hubs locked that I start getting vibrations above 65mpg. I just don't think the system is capable if running that fast with the front end locked in. Usually I unlock the hubs if I know I'm not going to be needing 4wd or if I'm going to be running at higher speeds.

 

What speeds were you at when this happen? Were you in 2 wheel drive or 4x4?

 

My truck is a F350 2000 with 160 000 miles. I was driving at 65-70 mph and in 2wd, but with the hubs locked.

 

Man, this is starting to get ugly!

 

Mr Woodward...How many miles on the blown Xfer case? Be interested to see inside of it. Sounds like snap ring or shaft bearing failure? Im fairly new to SD Ford. Im trying to learn where the week spots are. I know Jeeps. The New Process T Cases in certain years have a snap ring that can become unseated and do this type of damage. Its a simple upgrade to fix it as a proactive, precautionary measure. $65 dollar kit.
Any Ford SD T Case experts out there that might know this? The rock crawler and off road crowd usually are insightful here. Crawling will really find the weak spots quickly.
2011 to present is where my main interest lays but earlier knowledge will help others too.

 

Agreed its gettin ulgy! I wonder if lack of service has contributed to this? Seems like these failures are in vehicles with higher mileage. And also seem to be from the early 2000s. What model number/ brand of transfer case are in these trucks?

 

This thread references this problem, along with Mercon V being possibly implicated:

https://www.ford-trucks.com/forums/1...ners-read.html

 

GM transfer cases fail with much greater frequency, just not as spectacularly (I help out a couple snow removal company's with after hour truck repairs. Put TWO t cases in one gmc last winter, never any of the super dutys, and they run three times as many). Looks like a lubrication failure, I think the link about the mercon 5 might be in the ballpark.

 

This has been going on using mercon V and there saying its the fault of the oil. You guys should really read this from the diesel side.

https://www.ford-trucks.com/forums/1...ners-read.html

 

i wouldn't sweat it guys.iv never gotten much more than 110-120k miles out of the old BW 1356 cases either.no,they didn't explode but they might as well have.the problem with the old ones is,their pumps fail and the fluid cooks then it's all downhill from there.of course a used t-case just runs around $150-200 for the pre-SD trucks and just takes an hour or so to swap out,so it's no big deal for us.id just call around your local yards to see what you can find with a 30 day warranty and swap it out yourselves.it's a very straight forward job for any shade tree.

 

Sorry for he delay guys, after I shovel the driveway, I'll post pics of the carnage inside.

 

I run 65+ with the front hubs locked. No vibration, no issues.

T-cases do not come apart like that unless one of 2 things has happened. They were seriously abused or suffered from a bad lack of maintenance.

 

yes me too. If you think about it its just a bigger version of the NP231 they put in the wranglers, and those front axles are always spinning.

Mine is still OEM at 199,750 miles. Did a change with mobile one about 5k miles ago and I believe it was the first change! I believe what usually happens with chain driven aluminum T cases is that the chain gets some slack and slaps the case. But in 2wd with the hubs unlocked power should be driven right through, and the chain should be still.

The rebuild kit I like the most is made by Timken, under the brand DT Components. Its part number DTK 271 for the manual shift AND electric shift. Database says same for 99-08.

Could not locate one, but did find this:
http://www.ebay.com/itm/Transfer-Case-Rebuild-Kit-98-on-Ford-NP271-NP273-BK485-/321568530630?pt=Motors_Car_Truck_Parts_Accessories&hash=item4adefa60c6&vxp=mtr
New Genuine Morse chain:
http://www.ebay.com/itm/NP-271-NP-273-Transfer-Case-Chain-BorgWarner-HV-064-Dodge-Ford-/321647076312?pt=Motors_Car_Truck_Parts_Accessories&hash=item4ae3a8e3d8&vxp=mtr

My theory is that this type of destruction is more common with electric shifted 273 transfer cases as 4x4 is used more often. Even though its a part time case, I would not be surprised if many people flip that switch every time it rains. If you have to get out and lock the hubs, its a different story.

Yes, I run with my hubs locked if its snowing pretty heavy and im expecting to use 4x4. My dad bought my truck new for his company, and I was talking to his maintenance guy who had put the vast majority of the miles on the truck. He claimed the hubs were automatic on all new trucks! I dont think he ever locked the hubs once in 10 years! Maybe thats the reason my chain has no slack.