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 07:47 PM.