Catastrophic Transfer Case Failure Question
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Catastrophic Transfer Case Failure Question
My best friend's 2003 6.0L Diesel F-250, 4X4, Automatic Transmission, 6" suspension lift, 85K miles, just had the front driveshaft fail somewhere within the transfer case, splitting the case and causing some serious collateral damage in the engine comparment. She does not off-road the vehicle, and rarely engages 4 wheel drive. This was her husbands truck, who was killed last year in a tragic accident, and she's at a loss as to what to do. Is this a common occurence with these vehicles? I have a 2003 6.0L Diesel F-350, 4X4, Manual Transmission and 4" suspension lift, with 65K miles, and have never had any problems whatsoever. The dealer estimates the damage cost at around $4,000 as this isn't covered under the engine's 100,000 mile warranty. I believe this is a manufacturing or assembly defect and should be covered by Ford, but I have no way of knowing for sure. Anybody else seen or heard of this?
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First, welcome to FTE!
OK, it's lifted, so forget it ... in any way shape or form, forget it. That's going to be Ford's answer, and you have no recourse because the part in question is effected by the modification, as the warranty says
Are you saying the front driveshaft came away from the transfer case because the transfer case shaft broke? Or are you talking about the front-end?
OK, it's lifted, so forget it ... in any way shape or form, forget it. That's going to be Ford's answer, and you have no recourse because the part in question is effected by the modification, as the warranty says
Are you saying the front driveshaft came away from the transfer case because the transfer case shaft broke? Or are you talking about the front-end?
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In any event... if the 4x4 was not engaged, there's no way the driveshaft should have been rotating so I'm at a loss as to how it would split the T-case... if it was, then it has to go through the transmission before it eats at the engine, is the tranny fine? did the shaft bounce off the ground??? This sounds awkward..
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The driveshaft was rotating. Better take a look at the front hubs, they are probably locked, either from being locked or the needle bearings long ago left the planet. Either that, or she had it in 4H. There is no way a transfer case could break like that if the front driveshaft wasn't moving.
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I can't answer any detailed questions because I haven't actually seen the damage myself. I only know what she told me after she looked at it at the dealer. I do know that she doesn't have manually locking front hubs, but I agree that the front drive shaft shouldn't have been turning if it wasn't in 4x4, which she said she wasn't. I also agree that Ford will blame it on the lift, regardless of what may actually have caused the problem. It was actually the transfer case where the driveshaft failed, but I don't think it fell on the ground. Not sure about that either. But I was just wondering if others have experienced the same type problem, or if this is relatively rare.
Thanks!
Thanks!
Laughing Gas
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From: Denver, CO
I posted a similar question in the Explorer forum. My friends Exploder engaged into 4x4 on its own on the freeway and grenaded the transfer case. He took it to a transmission shop had a new transfer case put in and on the test drive blew the transfer case again. The shop replaced the T-case again for free and disconected the ESOF.
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Interesting end to the story. My friend called Ford Motor Company and spoke to a customer service rep, who agreed to send somebody out to take a look at it. Yesterday they called her and told her they were going to cover the entire cost of the repair (revised to almost $5000), but they wanted to keep all the old parts. She said "No problem"!! I still haven't heard what actually caused the problem, but my suspicion is the ESOF....Anyway, Ford certainly took care of this customer!
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From: Long Island USA
Originally Posted by rkdillinger
I still haven't heard what actually caused the problem, but my suspicion is the ESOF....Anyway, Ford certainly took care of this customer!
However, I wouldn't blame the ESOF - there's no difference between that and the manual transfer case, and nothing would happen if it came on unexpectedly....
I'd suspect the front output shaft of the transfer case broke...
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From: In my House
Which T-case does the super-duty use now? Is it still the BW-1356?. If it's the 1356, I have seen plenty of where the input shaft seal fails and allows cross-flow from the transmission into the t-case, which will overfill the t-case.
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From: Milky Way Galaxy
Originally Posted by 96f150
Which T-case does the super-duty use now? Is it still the BW-1356?. If it's the 1356, I have seen plenty of where the input shaft seal fails and allows cross-flow from the transmission into the t-case, which will overfill the t-case.
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From: In my House
WOW, I never new they got rid of that case......Guess that's what I get for owning a 150...haa. SO I guess its safe to say they stopped using that 1356 when they came out with the Superduty in 1999?
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From: Milky Way Galaxy
Oops! I probabley should've said 3/4 or 1-ton truck, since the 150's are definately full-size, sorry about that. But yes, the BW's were replaced by the NVG's in '99. I think Ford believed the BW's weren't up to the task of handiling the redesigned 7.3L diesel and the new 4R100 tranny, but that's just my guess.
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