:S, wow not good.

Thats a pretty sweet tcase bracket too.

are they tg 6.5's, if so lucky it has a lifetime warranty.

Never knew of this one?
I killed a set of 6.5's a few months ago (intermediate shaft bearing failure).

Grabbed a new case and rebuilt it with 6.5's again. I can't drive for shit offroad with big tyres and factory gearing.

What clauses are associated with the lifetime warranty?

Agreed.
Was just curious as I wouldn't have thought replacement due to the case failure above would be warranted either.

Possibly not, but It would be alot harder to determine that the gears failed as a result of the case flexing/ breaking; rather than a bearing failure.

A failed bearing will leave marks on the gear surface that it makes contact with. A broken case will most likely munch teeth first

I don't think the case failed first. It looks to me like the gears failed and the broken bits of teeth jammed between the gears causing enough force to split the case open.

If you look at the part of the case that broke off, there is almost no load applied to it by the mounts.

No amount of reinforcement or strengthend mounts is going to stop the gears splitting the case open when they run over bits of themselves, so I wouldn't blame the snatch mount.

Ben

Had a bit of fun at the first sand bowl, was really impressed with the new power. Night continued climbing in to the second sand bowl, which the entrance is a soft as dune climb with a bit of axle tramp bumps and it wenth half way up. Wasnt really doing anything stupid, was about 6000rpm 1st high. The gears are busted from the shaft movement and thus munching the gears.

One of my cases developed a crack similiar to yours , but didn't actually break , I'd say your case has flexed and the case has broken damaging the gear , your mount doesn't give solid support , it can still flex in the middle , allowing the case to seperate , Cheers Paul.

well i had a chance to pull down the transfer case tonight and inspect what was salvageable.


I've smashed the input gear, the custom made intermediate gear and the casing

but luckly the output shaft and both hi and low output gears survived

so just need to find a late 1L donor transfer case to make another one.

Anybody got one of these laying around that's going really cheap ??

the main problem is you have all that torque going through the t/case......yet the tailshafts and diffs are still having a hard time turning the wheels as they did before transfer gears, its just that everything forward of the t/case is having it easier. diff gears would help solve alot of the drama there.

the main problem is you have all that torque going through the t/case......yet the tailshafts and diffs are still having a hard time turning the wheels as they did before transfer gears, its just that everything forward of the t/case is having it easier. diff gears would help solve alot of the drama there.

+1
4.57 diff gears would be my preference, coupled with a 4.16 xfer case
Low 1st is same ratio as 6.5 low 2nd (cant recall using low first).

Pros
reduced stress on drive shafts, transfer case etc
improves speedo accuracy (ideal with 32' and very close with 7.5R16 or 235/85R16)
less likely to need fancy transfer case supports


cons
cost
combined high range reduction of 12% with 32s.
have to use 31-32 all the time
still not idiot proof

FYI

i had spread my reduction between the diff gears and transfer and still managed to split my case, I was running 4.1 transfer gears and 4.6 vitara diff gears with 33's. So i recommend bracing the transfer where you can !!