Originally Posted by ronjenx

This is the recipe for disaster:
Lifted
Regeared
After market front drive shaft with single joint at the pinion, double cardan at the t-case
An adapter at the t-case that increases the distance of the double cardan from the t-case.
Front pinion more than a few degrees out of alignment with the drive shaft
Highway speed

That's when you are tooling along, fat, dumb, and happy, (no offense, it's just an expression), then you suddenly hear the onset of vibration. Then, all of a sudden, KABOOM!
It's happened to quite a few JKers.

The thing that would prevent this is getting the front pinion and drive shaft into alignment. The double cardan at the t-case requires the front joint to be in alignment with the drive shaft.
But then, that can't be done on a lifted JK because you would have too little caster.

Originally Posted by ronjenx

It's not a t-case design flaw.

The common denominator in the t-case explosions is lifted, bad pinion angle, aftermarket drive shafts, re-geared, highway speeds. I'll even bet the OP's front drive shaft had a single, regular u-joint at the pinion, and a double cardan at the t-case.

This all adds up to hitting a critical front drive shaft vibration frequency, then KA-BOOM.
And the farther the t-case yoke puts the double cardan from the t-case, the easier it will be to hit that frequency.

This is assuming the t-case hasn't seen a trail impact or bent drive shaft.

Originally Posted by ronjenx

Another thing to consider:

When one replaces the front drive shaft with a shaft that has a double cardan joint at the t-case, the front axle must be rotated to get the front single joint as straight as possible. Trying to maintain caster may prevent that.
Having an angle on the front joint pretty much negates the benefit of the double cardan at the t-case. They are not perfect constant velocity joints. They have their own dynamic issues, and are a source of vibration, too.

Originally Posted by aldaman

Where is it leaking exactly? Is it leaking from the yoke area of the driveshaft or is there a hairline crack at the transfer case? Are you able to post pics. Also are you running an aftermarket front driveshaft, if so have you been experiencing any vibration at high speeds. I dont want to alarm you but there have been cases where having 5.13 gearing and 3.5" or more lifts have been a recipe for blown transfer cases running that combo and not having proper pinion to driveshaft alignment when using aftermarket DS...

Originally Posted by LeroyJMC

Are you the original owner? If so, then it's covered under lifetime powertrain warranty.

Originally Posted by aldaman

Here's a link to the transfer case explosion. Hopefully your issue is not the case, but a good FYI read.....

https://www.jk-forum.com/forums/jk-s...n-fire-171530/

https://www.jk-forum.com/forums/modi...ploded-138605/