Cheap insurance imo

 

No it was not in 4 wheel drive. We were just diving down the freeway. did not notice any vibration. Just a big boom and the shiftier started to bang agents my leg, pulled over. Looked under the jeep and the transfer case was in pieces. every thing I can find says it is caused from vibration but as I said before there was no vibration. I has after market drive shafts, not sure what brand they were on the jeep when i bought it. I am going to a atlas two speed transfer case so I don't have this problem again. Was just wondering how many others have had this problem. Just put the atlas in have to get the front drive shaft shortened.

 

Rear shaft worked fine? I've been thinking atlas also

 

This is what usually brings on a front T-Case explosion:

Lifted
Re-geared
Double cardan at the front of the t-case
Adapter on the t-case front flange, rater than the shorter replacement flange
More than a couple degrees from straight between front pinion and front drive shaft
Highway speed
Vibration (whether perceived or not)

Another factor is lack of lubrication in the front double cardan. This can cause the same result without any of the other factors.

How many of the above items can you say you have?

 

still need to check the length on the rear shaft, but it looks to be ok, the weather here is kind of nasty right now. waiting for it clear up a bit to finish. I bought the jk kit from advance adapters, gives you just about every thing you need to put it in. ( shiftier, cables electronics so all the lights in the dash work the way that should)

 

not sure what you are calling a cardan, the jeep is lifted, factory gears, fluid in the transfer case was good just had it checked about a month ago.

 

Double cardan refers to the double u-joint at the t-case.
By lack of lubrication, I was referring to the double cardan being dry from waiting too long to grease it.

The double cardan at the t-case needs to have the single cardan at the pinion be very close to straight. In other words, the pinion and the drive shaft must be no more than a couple degrees from being in line.

Your stocks gears are unusual. During the spate of t-case explosions a few years back, I don't recall seeing anyone having stock gears.

 

I always heard them referred to as c/v joints, and yes I have a double u joint at the transfer case and a single u joint at the differential. they were greased about a month ago when the fluid in the transfer case was checked.

 

C/V joint could also refer to Rzeppa joint, which is what the stock joint is.

 

People often skip maintenance on the centering ball of the DC.