Transfer Case Failure x 2

[SCF Truck]

We're a new Ram 2500 owner. We've had the misfortune of having our BW manual txfr case fail twice while pulling a gooseneck with 13,000 lbs. Any ideas what's happening? The truck has 1600 miles on it. FCA is investigating no word yet. We have our theories.

 

[JR]

Were you towing in 2 wheel drive when the failures happened? One failure is rare, two in such short order would leave me suspicious of something other than the TC.
What are your theories? Please keep us informed!

 

[Deleted member 995608]

That is rare. Keep us up to date.

 

[mweiman]

Exactly what is failing or breaking?

 

[SCF Truck]

Towing on the interstate hwy in 2wd.
Happened both times coasting downhill under engine breaking. FCA suggested we were overloaded. Sent proof from weigh station the load was well below our VIN 17,610 lbs.
MY theory is the shift linkage is misadjusted. Only getting partial gear engagement and clutch slippage. Under the engine breaking torque the txfr case gears unload and gears start breaking.

Dealer says tech ckd the linkage adjustment. I looked on the linkage jam nut and rod, saw no signs of any wrenching. See photo.

Were you towing in 2 wheel drive when the failures happened? One failure is rare, two in such short order would leave me suspicious of something other than the TC.
What are your theories? Please keep us informed!

 

[SCF Truck]

Exactly what is failing or breaking?

Total failure bent shift forks, broken gears, burned clutch. Not a pleasant experience very violent.

 

[Ozymandias]

Die you check yourself that the shiftlever has some way left in both directions.
Mean can you press ist a 1/2" forward in the 2Wd position and it goes back when leaving it alone.

Had that problem back in the days with my Jeep.

 

[jhenderson]

If you feel the detent when the case is shifted it’s not adjustment. Particularly since 2wd is not at either end of the pattern. There’s no type of clutch in your transfer case. You never answered the question of what’s actually broken in the case.

 

[SCF Truck]

If you feel the detent when the case is shifted it’s not adjustment. Particularly since 2wd is not at either end of the pattern. There’s no type of clutch in your transfer case. You never answered the question of what’s actually broken in the case.

There is an internal clutch mechanism to help shift from 2H to 4H while driving.

Dont know what broke. Dealer has both cases. They probably dont know.

 

[SCF Truck]

Die you check yourself that the shiftlever has some way left in both directions.
Mean can you press ist a 1/2" forward in the 2Wd position and it goes back when leaving it alone.

Had that problem back in the days with my Jeep.

Did not ck regrettably. Definitely will when we get the truck back. At this point I'm not planning on keeping the truck. Left me stranded twice and can't depend on it. We use it for our farm business.

 

[Newsa]

Total failure bent shift forks, broken gears, burned clutch. Not a pleasant experience very violent.

I've heard srories of the entire aluminum case (shell) shattering. Also a very scary occurrence i'm sure.

 

[Newsa]

If you feel the detent when the case is shifted it’s not adjustment. Particularly since 2wd is not at either end of the pattern. There’s no type of clutch in your transfer case. You never answered the question of what’s actually broken in the case.

Isn't the detent in the shifter itself? I've noticed that the g56 shifter has it's own built in detents in it that have little to do with whether the transmission is engaged properly.

 

[mweiman]

Accidentally shipped with out fluid? Then dealer didn’t fill the second one? What transmission and wheel base? Maybe check all engine and body mounts. Maybe something twisting and pulling it in and out of gear. Even at that I find it hard to believe it would destroy it. The bad part is I assume the old cases may have to end up back to bw for failure analysis.

 

[jhenderson]

There is an internal clutch mechanism to help shift from 2H to 4H while driving..

Not on our cases there isn’t. You have a Borg Warner 44-46 transfer case. It’s all gear and chain. No heavy duty case has any type of internal clutch. On all wheel drive vehicles there’s a clutch type differential that allows a little slippage for driving on hard surfaces but that’s not our trucks.

 

[SCF Truck]

Isn't the detent in the shifter itself? I've noticed that the g56 shifter has it's own built in detents in it that have little to do with whether the transmission is engaged properly.

That's a good question. IDK. You can see the plastic shifter poking through the floor board in thephoto. .

Not on our cases there isn’t. You have a Borg Warner 44-46 transfer case. It’s all gear and chain. No heavy duty case has any type of internal clutch. On all wheel drive vehicles there’s a clutch type differential that allows a little slippage for driving on hard surfaces but that’s not our trucks.

Dealer said it had a clutch. Makes sense for on the fly shifting. How does it function?

 

[DonFitzwater]

There are no clutches in these type transfer cases. I’m guessing if you have a decent dealer they will find an external failure source.

 

[Deleted member 995608]

Maybe Bob4x4 will chime in to clarify

 

[Ozymandias]

He talks about the synchronization unit.

 

[Ozymandias]

One couldn't shift on the fly without it.

 

[jhenderson]

Rethought my reply. It was unwarranted.