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trans to transfer case coupler chewing itself apart

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18K views 3 replies 3 participants last post by  jefo  
#1 · (Edited)
I haven't been able to find anything similar, but has anyone had/seen anything like this happen before?

Last summer (about 6k miles ago) I had my original trans and transfer case chew up the coupler between them. I noticed a sort of rumble strip feeling and took things apart to find this. At the time I chalked it up to the incompetent local dealership claiming to have replaced the output shaft bearing (found pieces of it's cage in the pan), but failing to do so. This was right under 70k miles.

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Fast forward to this week and I pulled away from a stop at WOT and got a loud and violent (shaking) grind. The car drove normal if you didn't give it much gas, but when I went to pull up my steep driveway it finally let go.

This time the splines were even more stripped than the original trans and tcase, but the coupler on the output shaft of the trans also sheared off.

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The car is a 14 Charger R/T. I've got some basic mods, 6.4 intake, shorty headers, cat back exhaust, and a diablo 91 tune, so not making all that much power. Also running 255 width michelin as3+ tires. I'm gonna wind up replacing the transfer case and likely the transmission again due to the damaged splines on the output shaft, but now I'm wondering how long it's gonna last.

I greased the splines well on that coupler last time. I don't launch/beat on the car all the time. I just don't understand why I'm having this happen now, especially 6k miles on a trans and transfer case that only had 4k miles on them when I got it.

Anyone ever see anything similar or have some idea as to something I'm doing wrong here?
 
#2 ·
It looks like the nut spun through the stake points in the third photo? I would think that loosening up could cause the damage seen in the 2nd case. I see you have the guide dowels so it isn't an alignment issue.

I have been researching this for my car as I noticed some spline wear when I pulled the transfer case. The nut was still staked on mine but was loose... the nut/gear had worn enough over time from rocking on the splines to lose the torque spec.

There was a fix part for the 05's back in the day which fits through 2014 models:
68000503AA - Dodge Flange package. After [10/19/05], up to [10/19/05, up to [10/19/05] | Factory Chrysler Parts, Bartow FL