Blown front driveshaft

[Jwithing]

Month or two ago I was driving down the highway and heard/felt an immense bam! In the floorboard. Pulled over as soon as safe, which was a few miles. Heard another loud thud shortlt before pulling over.

Front driveshaft obliterated at the cv joint to slip yoke at the transfer case.

Took the driveshaft off, put the truck in 2wd, abandoned my plans and headed to the scrap yard. Picked up a new driveshaft and flushed the tcase as I noticed fluid blown back behind the case and I was already doing the diffs anyway.

Checked a couple days later and there appeared to be drops at the bottom of the tcase housing. Took it to a local tire shop that has some good mechanics. They told me it was a bad seal at the drain plug. Drained and refilled.


Just changed my oil and noticed my passenger side front diff bracket is broken clean in half.

I also checked the tcase and still have a couple drops collecting at the bottom of the tcase. In hindsight, I don't think the mechanics got the full story and fully checked over my tcase for cracks or bad seals.

Am I screwed needing a new front diff? I don't think its safe to drive, even in 2wd, right?

 

[Wild one]

Month or two ago I was driving down the highway and heard/felt an immense bam! In the floorboard. Pulled over as soon as safe, which was a few miles. Heard another loud thud shortlt before pulling over.

Front driveshaft obliterated at the cv joint to slip yoke at the transfer case.
View attachment 586344
Took the driveshaft off, put the truck in 2wd, abandoned my plans and headed to the scrap yard. Picked up a new driveshaft and flushed the tcase as I noticed fluid blown back behind the case and I was already doing the diffs anyway.

Checked a couple days later and there appeared to be drops at the bottom of the tcase housing. Took it to a local tire shop that has some good mechanics. They told me it was a bad seal at the drain plug. Drained and refilled.
View attachment 586346

Just changed my oil and noticed my passenger side front diff bracket is broken clean in half.

View attachment 586345 I also checked the tcase and still have a couple drops collecting at the bottom of the tcase. In hindsight, I don't think the mechanics got the full story and fully checked over my tcase for cracks or bad seals.

Am I screwed needing a new front diff? I don't think its safe to drive, even in 2wd, right?

You can remove the front diff / CV axles and front driveshaft and drive it till you can hunt up a new diff,or a "very" good welder who can weld the diff bracket back on. Just leave it in 2 wheel drive mode. I took the front diff/cv's and front driveshaft out of my 4X4 10 years ago, as it was a pavement princess and i never used it as a 4X4

 

[Jwithing]

You can remove the front diff / CV axles and front driveshaft and drive it till you can hunt up a new diff,or a "very" good welder who can weld the diff bracket back on. Just leave it in 2 wheel drive mode. I took the front diff/cv's and front driveshaft out of my 4X4 10 years ago, as it was a pavement princess and i never used it as a 4X4

One good thing I suppose is that I have the 1/4" skid plate directly under the diff with the lift kit. I assume this has been my saving grace. I suspect I've been driving with it like this for almost 2 months and regularly towing 8k lbs. If anything, the cv axels are getting a slightly better angle lol. That said, I should probably disconnect the front driveshaft again at the absolute minimum?

 

[Wild one]

One good thing I suppose is that I have the 1/4" skid plate directly under the diff with the lift kit. I assume this has been my saving grace. I suspect I've been driving with it like this for almost 2 months and regularly towing 8k lbs. If anything, the cv axels are getting a slightly better angle lol. That said, I should probably disconnect the front driveshaft again at the absolute minimum?

You'll also want to remove the CV's,as they're always turning and putting a load on the front diff,more so then the driveshaft.

 

[Ken226]

Month or two ago I was driving down the highway

Took the driveshaft off, put the truck in 2wd

Just out of curiosity, these two sentences in your post give the impression that you had 4wd engaged, while on the highway? At highway speeds? Or am I just reading it wrong?



Does your truck have the 44-44 transfer case with 4 auto?

 

[Jwithing]

Just out of curiosity, these two sentences in your post give the impression that you had 4wd engaged, while on the highway? At highway speeds? Or am I just reading it wrong?



Does your truck have the 44-44 transfer case with 4 auto?

I have the 44-44 and was in 4 auto BUT, you just got me thinking... I have the 4wd switch from Brandon and put it in a pretty stupid place. Its on the driver side of the center console towards the radio on that little panel that pops off. You know... right about where your knee bangs against the panel. Wouldn't be the first time I accidentally turned it on. Quite possible I bumped it while going down the highway. Been thinking about relocating it for years, sounds like now is the time.

 

[Jwithing]

You'll also want to remove the CV's,as they're always turning and putting a load on the front diff,more so then the driveshaft.

Damn, I don't think I have time to disconnect cvs. Going to have to get a rental.

Got a new front diff and tcase both with 95k miles ordered for $1,450. Cheaper than I thought but under 120k miles increased price by about $650. Also glad to see that the intermediate shaft kits with the boots are readily available by several sources and no longer $500+.

 

[Ken226]

I have the 44-44 and was in 4 auto BUT, you just got me thinking... I have the 4wd switch from Brandon and put it in a pretty stupid place. Its on the driver side of the center console towards the radio on that little panel that pops off. You know... right about where your knee bangs against the panel. Wouldn't be the first time I accidentally turned it on. Quite possible I bumped it while going down the highway. Been thinking about relocating it for years, sounds like now is the time.

On my CNC mill there are a few toggle switches that if inadvertently flipped at the wrong time, could result in losing body parts. For those spots, I use something like these.



Or, the raised wing type.

 

[Wild one]

I have the 44-44 and was in 4 auto BUT, you just got me thinking... I have the 4wd switch from Brandon and put it in a pretty stupid place. Its on the driver side of the center console towards the radio on that little panel that pops off. You know... right about where your knee bangs against the panel. Wouldn't be the first time I accidentally turned it on. Quite possible I bumped it while going down the highway. Been thinking about relocating it for years, sounds like now is the time.

2 months ago the roads in your area should have been okay,so why did you have it in 4 Auto?

 

[crash68]

2 months ago the roads in your area should have been okay,so why did you have it in 4 Auto?

I was wondering the same thing, if one is able to travel at freeway speeds there's no need for 4X4