t-case cracked after swap

[btimm86]

A rattling sound was coming from my 95 explorer transmission/ transfer case for the past couple years. Recently on the highway when i let off the gas there would be a large escalating grinding sound coming from the transmission/transfer case area. I thought a trashed bearing was the cause so I swapped in a junkyard BW1354 in place of my electric shift 4405. during the swap I noticed a large amount of atf leaking from the intermediate housing between the transfer case input and transmission output shaft. I also noticed the transmission output shaft had some play in it and figured that was my trashed bearing. So i fire up my explorer put it in drive then in park and I hear the same grinding sound from the transmission (the t-case was in neutral). I then put the t-case in 4low and try to put the truck in drive and reverse. The car moved fine under idle for about 5 feet before there was a binding feeling and finally a pop. Transfer case cracked wide open originating at the rear driveshaft output. - Do you think the transfer case was already cracked? I don't know how it would see this stress idling.

 

[ExploringNC]

I have a TC with worn out forks that is looking for a new home if you need the case.

 

[Rick]

Did it look anything like this:

I have no idea why it did that. I had just finished with a relatively easy day of wheelin' and was driving out on a flat dirt road when it just busted wide open...

 

[btimm86]

yup pretty much the same thing