Greetings,


Yesterday my brother-in-law annihilated the transfer case in his 2000 V10 Excursion.



His truck is lifted about 10-12” and is running 39” Super Swampers. He was climbing a big hill when all hell broke loose. It sounded like a bomb went off. Long story short – there is a 2.5” hole in the transfer case now. >>


Two questions:



1: What is the strongest transfer case that will fit this truck?



2: Are there any other week spots for these trucks?





Thanks Guys, FTE is the BEST!!!!!

 

Couple of questions.

What gears are in the truck?
Was he in 4HI or 4LO?

The transfer cases in Excursion is fairly strong provided it stays in the optimal RPM range. If you lift but don't re-gear the axles it can cause havoc like what you describe.

Another weak spot for serious wheelers is the Dana 50 front axle. Necked down half shafts...yuck.

 

Let me guess. The truck started bouncing/hopping a couple times before he grenaded the Tcase??? He didn't let off the throttle and BOOM!

39" tires + Stock gears + Aluminum Tcase + heavy on the skinny pedal + 7500lb vehicle= Expensive parts fix.

 

Here you go:
1) NP-205, but you're going to have to make your own linkages and I think the rest will just bolt up but i'm not sure. Flanges and splines should work. Advanced adapters will know.
2) Yes. Front wheel bearings, front ball joints, front auto hubs, and that 4r100 trans.

 

The transfer case should be the same model used in the Superduty Trucks. This is the strongest gear box of any light truck out there. Noticeably stronger than even a built NP 205, even though it is chain driven. You cannot go stronger than what you've got. It is being pounded in about the burliest thing imaginable so if you could ever push it to the limits, i'd say it just got there. Is it possible it was low on oil & the angle took the lubrication away from the gears so it got too hot & bombed?

 

1: Not sure about the gears - the truck is at shop 75 miles away.
2: He is sure that he was in 4 wheel “Hi”

What gear ratio should he be running for these tires?

 

A V-10 on 39's will need low gearing, especially if it is an off road rig. Depending on what he wants for power vs. economy (which is almost out the window,) he should be running at least 4:56 for strong low end 4x4 power. If he wants supreme off road capability & doesn't mind some high RPMs on the highway, he could go as deep as 5:38s, but that is also gonna put allot more torque through the drivetrain.

Those are big tires but a strong engine. Not as flexible in gearing it as with a diesel. Did he get it stock with 4:10s? I think it was only the pickups that came with 4:30s. Those would be more highway friendly for a V-10 but lack some power. Things can really vary with how he drives it & what kind of terrain he drives. For example in sand he won't need low gearing nearly as badly as he will in mud or rock crawling.

If he was climbing a steep hill that was rough & causing some wheel hop he should have been in 4 wheel low range. That way he won't have to mash the pedal as far to have the power he needs to drive the tires. Having to make the tires go fast is harder on the drivetrain because once a slipping tire catches, it is suddenly slammed with the contact of traction. This will also encourage bouncing. Bouncing at hard throttle=breaking. Even 3/4 & 1-ton parts are going to be put to their limits in such a huge vehicle.

 

I was able to bolt an NP-205 to my E4OD, but the front output was too close to the pan rail.Would have had to run a small yoke & u-joint.

Like 7.3 Ex said, I also read the SD t-case was about the strongest thing out there.But some guys can break an anvil w/a glass hammer!LOL

Brian

 

been there done that twice! tell your brother in law he needs a front drive shaft modfied to fit the lift, I bet he bottomed out the the slip on that front drive shaft and pushed the case back.

 

where can you get a transfer case?

I need one for my 4x2 to 4x4 conversion.
I been looking in junkyards with no luck. I really do not want to go through a stealership for one. yikes

thanks

Chris

 

cumminpwr11,

Junk yard, eBay, dealership. The cheapest thing to do is probably to divorce mount an NP 205. If you go Ford, the easiest thing would be to get a transmission with a transfer case already mounted & use that whole setup.

Simplest would be one with the manual levers, otherwise you'll be getting into the electric lever & may get into the vacuum operated hubs, etc. Look for an NV 271 or 273. I'd go with manual hubs like Warn & a stick shift transfer case. I think even the newer GM transfer cases are driver's side so you have options.

I've got an Excursion Dana 50 with suspension i may be willing to sell. May even be ditching my entire drivetrain for my Cummins 12 valve & an Allison 1000, not sure about my transfer case though.

 

7.3
I have a common rail in my cummins in my garage right now. I am going through Suncoast to have a built proof tranny built, and I have not desided where I am going to run a 4r100 or a dodge tranny. The tranfercase is my main concern right now. I want reliable, so I am stumped.

I would like to have a floor ship. so a NP 205 might just be the way to go

THANKS

Chris

 

What does it take to get a dana 50 beefed up. I was looking for a 60 because I heard bad things about 50's.

I have a dana 60 in my dodge and I bogged and jumped the hell out of that truck and never a problem.

I am interested anyway though. let me know