Cracked extension housing... Help!!! - Ford Powerstroke Diesel Forum
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Old 06-01-2012, 06:43 PM
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Exclamation Cracked extension housing... Help!!!

I'm hoping that someone on here will be able to give me some advise/ theorize with me about what's going with my truck. I have a 2008 6.4l super cab short box f-250 with a 4.5 rough country susp lift and 35s with 58k miles. The engine is not programmed and is stock other than an Afe cai. It is at the dealership getting the tailshaft/ extension housing fixed for the second time in the past month. On both occasions I was driving at a steady 50 miles an hour or so, normal driving conditions, not beating on the truck at all, and I hear a bang as if I'd ran over something and the truck looses all power to the wheels. After looking under the truck the extension housing (where the 4wd transfer case connects to the back of the tranny) had been cracked completely from where it mounts to the tranny. The truck has a one-piece drive shaft and I was thinking that since it is such a short drive shaft compared to cc and long box that the 4.5 lift changes the angle of the drive shaft too much or/and maybe pulls on the drive shaft since the rear diff is further away than it would be on a truck with stock height. I'm considering getting a two piece drive shaft custom made and putting a carrier bearing drop on it. Just wanted to see if anyone else had any ideas or suggestions on what's causing this and how to fix it before I dump a bunch of money into trying a two-piece driveshaft. Thanks in advance and any help would be greatly appreciated!!

Last edited by psdiesel08; 06-01-2012 at 06:47 PM.
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Old 06-04-2012, 08:43 AM
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anyone?
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Old 06-05-2012, 05:25 AM
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psdiesel08--I'm by no means a mechanic, but I do have experience with lifts. If you think about it, the angle increases greater on your truck than a CC due to the shorter shaft. I'm more than willing to bet it's due to the lift, and connecting to your TC.

Try the two piece drive shaft and/or traction bars. these trucks but out serious torque that is rough on your major components when lifted.

Hope this helps.
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Old 06-06-2012, 01:53 PM
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Thanks for the reply! That is what the general consensus seems to be with a couple of my buddies and the guys at the dealership. The only reason why we're not 100% sure this is the issue is because it would seem that if this was the case it would be breaking between the 4wd transfer case and the driveshaft rather than between the tranny and 4wd transfer case. But you are definitely right about the angle of the driveshaft as compared to longer trucks. A cc could probably be lifted over 8" before the driveshaft was as steep as mine. I just find it weird that I've never heard of people having this issue lifting a super cab short bed before. Has anyone else??
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driveshaft, drivetrain, extension housing, tailshaft

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