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These definitely grenade like yours --- have a personal experience with a NP205 Transfer Case going totally ape**** in a heavily modified Dodge Truck I own --- built LA, modified 518 (3" longer than the 727 it replaced), other drive line mods (driveshaft lengths).
Jeeps are far worse -- loads of issues (my wife's Wrangler had one fixed under warranty)
Driving with the hubs locked won't do that if everything is working properly, I have seen those failures before and they are either caused by a worn or out of balance driveshaft, bad u joint or low on transfer case fluid.
I've never messed with the 4WD vehicles, is this why guys go to manual hubs? Does the 4wd system not actually have a way to sense when the auto hubs are locked/unlocked?
All the 4x4 system does is engage and disengage when you tell it to, or do it yourself if you have a manual shift transfer case, It has no way of sensing anything.
Is there a different more robust transfer case that would work in our applications? B.
They are already one of the strongest transfer cases ever made, some may argue an NP205 is better because it cast Iron case but I have seen them both hold up fine to over 1000 hp, the NP205 low range gear isn't as good either only 1.96 vs 2.72 for the NV271/273.
Anyone know what they are running in the new Superduties? 1000+ torque I wonder if they are still using the NV273?
It will handle that no problem but they quit using those a few years ago because New Venture went out of business. The new ones use a Borg Warner transfer case.
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