LX AWD Shop Level 1 Transfer case UPDATE

[alpinewil81]

I believe the only TSB for the transfer case is the removal of the friction disc on top of the planetary gear set. So yes it sounds like it was done. Shuttering usually after that is done only happens when the front wheels are spinning faster than the rears, that or something is broken.

Not shuddering. If you look, I said specifically internal chatter. I've had all that done with the shuddering issues and such. My parts list includes the new tranny, t-case, tq converter, upper control arms, struts, shocks, springs, cv shafts... and the list goes on. She rides like crap but at least she isn't falling apart anymore other than the t-case again.

No, what I'm talking about is inside the t-case. I was told there is a ring or clip or something internal known to break or loosen. When it does, a chatter under light loading becomes obvious. It sounds like a nut bouncing off the side walls of the main housing while you cruise along. Think similar to a spun bearing on a crank at idle. Under load, its gone. Its something inside the case that becomes quieted when the additional torque is present. Makes me wonder if it truly is a bad gear or bearing within.

I'm not sure what it is exactly, but its a noted concern with Chrysler. This is my second t-case to do it... I'm just gonna drive it till she dies. No point in replacing it again if its going to do it again. I love my car, but Dodge drivetrains aren't exactly bulletproof. Statistically they are amongst the worst of the big three for long term dependability. Most noteably in trucks though. No point in changing it just yet if its still getting the job done at least.

Edit: I may not want to replace it now... but I will in the future, hopefully with something that will last longer than 30k miles.

[tank8289]

Not shuddering. If you look, I said specifically internal chatter. I've had all that done with the shuddering issues and such. My parts list includes the new tranny, t-case, tq converter, upper control arms, struts, shocks, springs, cv shafts... and the list goes on. She rides like crap but at least she isn't falling apart anymore other than the t-case again.

No, what I'm talking about is inside the t-case. I was told there is a ring or clip or something internal known to break or loosen. When it does, a chatter under light loading becomes obvious. It sounds like a nut bouncing off the side walls of the main housing while you cruise along. Think similar to a spun bearing on a crank at idle. Under load, its gone. Its something inside the case that becomes quieted when the additional torque is present. Makes me wonder if it truly is a bad gear or bearing within.

I'm not sure what it is exactly, but its a noted concern with Chrysler. This is my second t-case to do it... I'm just gonna drive it till she dies. No point in replacing it again if its going to do it again. I love my car, but Dodge drivetrains aren't exactly bulletproof. Statistically they are amongst the worst of the big three for long term dependability. Most noteably in trucks though. No point in changing it just yet if its still getting the job done at least.

Edit: I may not want to replace it now... but I will in the future, hopefully with something that will last longer than 30k miles.

Mag-yum has broken a factory snap ring under load. Thats why my transfer cases come with thicker stronger ones now. Could be a possibility but im not sure. Only way to know is if it was opened.

[alpinewil81]

That sounds about like what I've been told? A snap ring or something. Problem is no dealership will open the case as it is 'sealed' according to their service description.

However, maybe a good tranny tech/shop would be a good place to take it. I'm not sure out tranny shop is still open... but I'll take a look in the phone book.

I'm seriously interested in a bullet proof drivetrain as I some day plan on adding a supercharger (next summer likely) or even stroking beyond a 6.1 L... maybe the 6.4 kit. Based on my experience and service numbers, I'll do so with aftermarket parts. I won't rely on the AWD OEM stuff to hold together. I know its worked for some, but it obviously isn't working on my tank. Darn the luck...

[tank8289]

Just an update that i have begun the CAD FEA (Finite element analysis) and design of a stronger transfer case. Hopefully i sould have a few prototypes out in the coming weeks. I will keep everyone updated. I will post up some pictures of what i have soon.

[richerdk]

bump! Im going to need a backup t-case soon haha

[warbly]

bump! Im looking for a cheep Tcase fluid, here in Canada stealership want $109, fluid can't be shippied from US to Canada

[tank8289]

So far the LVL 1 transfer case has held up against a 11.1 @ 127 run!

[Votsor]

So far the LVL 1 transfer case has held up against a 11.1 @ 127 run!

Congrats, thats great, I assume its direct replacement? and how much would you be able to send one out for? Also for curiosity how much HP/TQ is the car putting down? And besides the transfercase/transmission what other things on the AWD need to be bulked up to handle hard launches/power? Thanks.

[tank8289]

Ok Let me make this simple and summarize.

Parts needed to replace for >550 Crank HP
Transmission (I have a Paramount Performance)
Transfer case (LVL I will suffice for now)

That is all I have replaced so far without any problems with other parts (Drive shaft, and half shafts are fine no problems.)

My car Put down without the nitrous 550AWHP/560AWTQ? I dont remember off the top of my head its posted on the forum somewhere.

I can do a direct replacement transfer case but that would be VERY pricey depending on if you wanted a brand new transfer case or used one.

New Transfer Cases cost $3500+
Then add on the cost of the LVL I process Which is roughly $1400
Total price $4900 Which is Insane

Used Transfer cases go for around $400-600
+$1400 Process
Total price $1800-$2000
And you still have your factory one

The Best option is to send me your transfer case then you will only pay the $1400 LVL 1 Treatment process.

The entire process takes 2-3 Days for the treatment ALONE.
Then there is shipping time, Disassembly, and Assembly.
Turn around time is optimistically 7 Business Days.

[Votsor]

Thanks, Ill save my money, and send mine in to you, I have trust in your process, my brother is planning to do a 392 stroker, so I need something to hold the power, but thanks, thats amazing

[alpinewil81]

I like that price. My question now is what all does the Level I process include. I saw somewhere about cad work, are you replacing gears/sprockets and other parts with something new or what?

[tank8289]

Level I is a Thermal material Treatment process. It Includes dis assembly, bearing and seal removal, Thermal treatment process, seal replacement, bearing re installation, and complete reassembly.

Level 2 is still under works. I have put that on the back burner for now because quite frankly I'm not even sure it might be necessary. Level 2 is going to be quite expensive to not only create a prototype, but to also completely manufacture so until Level 1 has seen to not be enough i will start this up again. I have done all the necessary research to start the project up and have a prototype out in a few days.

[Votsor]

Level I is a Thermal material Treatment process. It Includes dis assembly, bearing and seal removal, Thermal treatment process, seal replacement, bearing re installation, and complete reassembly.

Level 2 is still under works. I have put that on the back burner for now because quite frankly I'm not even sure it might be necessary. Level 2 is going to be quite expensive to not only create a prototype, but to also completely manufacture so until Level 1 has seen to not be enough i will start this up again. I have done all the necessary research to start the project up and have a prototype out in a few days.

I agree, I dont see too many awds throwing down anywhere near that much, so there wont be demand yet, but I think this could be used as testing the waters for the rest of AWD racers, and it could give us time to see how good the lvl 1 is and what we could improve on, as for me, I am going to install cam after I do a dyno tune, and nitrous, but DEF set my sights on the tcase, and started saving, I remember when people were saying awds cant put the power down because of the transfer case, and that wasnt that long ago, and now theres one holding up to low 11 sec runs

[alpinewil81]

I agree, I dont see too many awds throwing down anywhere near that much, so there wont be demand yet, but I think this could be used as testing the waters for the rest of AWD racers, and it could give us time to see how good the lvl 1 is and what we could improve on, as for me, I am going to install cam after I do a dyno tune, and nitrous, but DEF set my sights on the tcase, and started saving, I remember when people were saying awds cant put the power down because of the transfer case, and that wasnt that long ago, and now theres one holding up to low 11 sec runs

Second that! Got headers coming, then its a new torque converter. Several retunes on the dyno in their as well. But when its time to get sirius, this is going to happen. If I have any more transfer case problems after already having lost a couple... then count me in any sooner.

Keep it up!

[Votsor]

Second that! Got headers coming, then its a new torque converter. Several retunes on the dyno in their as well. But when its time to get sirius, this is going to happen. If I have any more transfer case problems after already having lost a couple... then count me in any sooner.

Keep it up!

exactly, the only problem with awd in my case is the cv boot/half shaft keeps popping out and breaking, but hopefully there wont be a 3rd time, Yea Im def going to get a converter, any recommendations?