Transfer Case and 4WD

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Transfer Case and 4WD - 2/11/2004 9:29:51 PM    jenkinst   Posts: 5 Joined: 1/12/2004 From: United States Status: offline Ok it was snowing and I put my D in 4wd, then after I was finished I put it back to 2wd. But the 4wd didn't disengage. While driving down the HWY the differential popped and the seal/plug busted out along with all the fluid. Luckily I was within range of a Dodge dealer. (A known rip off dodge dealer). Anyway, after a $98 look-over they said I need to get all four tires the same brand and the tread has to be exact. The said 1/32nd of an inch will cause problems in 4wd. that’s a small amount; my tire could be sitting on some bubble gum. The result, it could ruin the transfer(s). Under inspection the gears are not black as they said they would be bad. My end result was an estimate for an overhaul/service to the transfer and drive. This would cost minimum of $360 and a max of $2,500 to repair/replace. How can I isolate or test for a problem so I don't get taken. What would cause the differential seal to pop and the fluid spill out? Thanks for any help. _____________________________ 98 Durango 4x4 5.9L 120,000 Miles Post #: 1

RE: Transfer Case and 4WD - 5/22/2004 3:52:42 AM    Saint   Posts: 393 Joined: 5/22/2004 From: Camp Pendleton Status: offline That's BS about the tires effecting performance in 4wd. Yes a big difference can cause problems, but 1/32 of an inch is BS, because your tires naturally wear unevenly 1/32" difference can happen during normal driving conditions. As far as the diff seal popping, I don't know, it's possible that the stress in the transfer case force enough pressure to pop the seal out, but I doubt that was the problem. Other than that I'm stumped, I've never had that problem with any 4x4 that I've ever worked on _____________________________ 2005 Dodge Ram 1500 4x4 Bright White 5.7L Hemi USMC-Diesel Fixer One Mind, Any Weapon-Marine Corps Martial Arts Brown Belt Instructor (in reply to jenkinst) Post #: 2

RE: Transfer Case and 4WD - 5/23/2004 1:46:54 AM    dodgemech   Posts: 788 Joined: 2/22/2004 Status: offline Saint-1/32 will cause issues. We replace PTO's all the time for uneven wear on caravans. When dealing with 4X4 and AWD it is crucial to keep up on tire maintence. BTW-if you are under warranty and have a 4X4 or AWD problem and the tires are worn unevenly you will be denied warranty. Jenkin-alot of time if after you shift into 2WD the light doesn't go out: you should pull over and place trans into rev, then back up 10-15 feet and try going forward again. You should feel it "pop" out of gear. My guess as to why you blew it apart is that it was stuck in 4X4 and you can't drive around like that, it doesn't have a viscous coupling so it will break. (in reply to Saint) Post #: 3

RE: Transfer Case and 4WD - 5/23/2004 3:34:19 AM    Saint   Posts: 393 Joined: 5/22/2004 From: Camp Pendleton Status: offline I still gotta disagree with the 1/32. I only work with 4WD vehicles, HMMWVA1s, HMMWVA2s, and multiple Rough Terrain Forklifts. If we have a problem with one tire we replace only the one tire, it doesn't matter how worn the other tires are. I've never seen or heard of a problem with the 4wd systems in any of the gear that I work on. _____________________________ 2005 Dodge Ram 1500 4x4 Bright White 5.7L Hemi USMC-Diesel Fixer One Mind, Any Weapon-Marine Corps Martial Arts Brown Belt Instructor (in reply to dodgemech) Post #: 4

RE: Transfer Case and 4WD - 5/23/2004 12:43:55 PM    dodgemech   Posts: 788 Joined: 2/22/2004 Status: offline Yeah I used to maintain the HUMVEE's at my unit, totally different system and much more tolarent of abuse than the NV series cases. They will grenade with different worn tires at diff positions. (in reply to Saint) Post #: 5

RE: Transfer Case and 4WD - 2/12/2008 11:01:25 PM    RamItOne Posts: 4501 Joined: 12/26/2007 Status: offline hrm so we shouldnt cook our tires????  (in reply to dodgemech) Post #: 6

RE: Transfer Case and 4WD - 2/16/2008 6:35:36 AM    Kensai Posts: 1669 Joined: 12/30/2003 From: United States Status: offline If our trannies are that sensitive to tolerances, no wonder everyone seems to have tranny issues!  Just one tire slightly offsize from another tire can destroy an axle, transfer case, etc.  Not good.  I agree, 1/32 is way too sensitive. _____________________________ Black 2000 Durango 5.9 R/T Fastman 52mm ThrottleBody Fastman custom built Tranny Castrol Full Syntec OEM K&N Air filter Monroe Reflexes BFG Comp T/A''s Champion IR Truck Plugs 180 Stat Hypertech III (87 oct) Custom Made Ram Air Intake (in reply to RamItOne) Post #: 7

RE: Transfer Case and 4WD - 2/16/2008 8:37:12 AM    Duranged408 Posts: 263 Joined: 1/6/2008 Status: offline I have to jump on the bandwagon as well, i disagree on the 1/32nd issue. I've never heard such a thing and can honesty say iv'e clocked 10k + miles on tires if not more than a 2/nds difference in 4hi without issues. I agree with the reverse proceedure mentioned, everytime i switch back to 2wh i always reverse for a little bit just to make sure. The main question i have is, by "Seal/Plug" Do you mean the actuall diff/drveshft seal? Or "plug" as in check fill? (in reply to Kensai) Post #: 8

RE: Transfer Case and 4WD - 2/18/2008 11:46:18 AM    hydrashocker Posts: 1789 Joined: 6/12/2005 Status: offline I call I call the problem was AXEL BIND and it was admitted. The tires were not the culprit here. _____________________________ 1998 Durango, 5.9L Built Motor Bored 20 Over, P&P Heads, K&N Ram Air CAI, MSD Ignition, 52MM Fastman TB, Built T-Case, Custom Built Trans, Air Bags, Magna Flow 3" Cat Back Exhaust On and On! (in reply to Duranged408) Post #: 9

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