Engine/Transmission (1998.5 - 2002) Transfer Case Broke in Half

[rono]

Well, I found out why my son's truck broke down '02 2500 auto. The U-joint closest to the front of the transfer case went out, flopped around and broke the transfer case in half. He said there was a vibration that was shaking the truck and before he could get stopped there was a very loud noise and the truck coasted to a stop out of gear.



I will take some pictures tonight and post them.



Now, where can I find both halves of the case? It looks like everything inside is ok. Also where is the best place to get the U-joints for the strange assembly on the front drive shaft? I checked with Dodge and they want over $500 for the front half only.



Much thanks for any info.



Ron

 

[Partyat33]

Transfer case express has been good to deal with.

 

[Scrappy]

where exactly did it break? you will probably have to at least replace the chain if it broke where it sounds to me like it did but I would be that most of the guts will need to be replaced also if it came out of gear. The joint you mentioned is a double cardan joint It uses the same design u-joints but has a Ball and cup in between them to keep the shaft centered. I am not sure if the u-soints are replaceable but I think you are going to have to replace the whole driveshaft because I be the Ball and cup is damaged and/or the shaft got bent. I would thave it checked by a driveline shop to see if it is bent and if it is repairable.

 

[WDixon27]

i rebuilt one of those double u-joint cv's on a late model jeep, it's a pain in the butt compared to doing a normal u-joint but it's about the same process, i did it all in a bench vice with sockets as spacers

 

[rono]

Partyat33, thanks for the info on Transfer Case Express, they had what I need and the price for both halves was less than what Dodge wanted for only the front half. They are going to 2nd day it so I can 'maybe' get it back together Saturday. Thanks!



Scrappy, you were right on. The U joint in the Carden assy. broke. I found parts for the Double Carden Joint and a kit to replace the ball inside. The chain didn't break, the case is busted open enough that you can see inside and see the chain and gears. After my son found out what was wrong, he had to move the truck, put it in drive and drove it a little ways to get it out of the way of others. Of course all the oil came out and he didn't have to move it but about 100 yds.



WDixon27, a vice and sockets is what I've used before on other joints and hoped that it would work on this one. I does look like a pain but there is no telling what that part would cost to replace, so I'm going have to try to fix it.



Thanks for everyone's input. I'll try to take pictures tonight and post tomorrow.



Ron