Transfer case carnage

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Trollhole

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Finally got it rebuit this weekend and with no bolts left in the new housing that was cracked when I bought it. (didn't see the crack) Anyway I had it welded and is good as new. The replacement had some pretty torn up gears. My gears in the original case that I had droped a bolt in into fair a lot better than this one. I guess I was lucky.
Mosy likely was the permatex that was used caused the problems. The PO had used so much of it that it squeezed out and into the case clogging the oil passages causing excess heat and failure.

Too much can be a bad thing.
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That crack came from the inside out, and it was from something that got wedged under the idler gear. For sure.

As far as the missing teeth on the hi speed gear, that is a situation common to transfer cases made between April of 1975 and January of 1976 exclusively. Now you know the exact vintage of that case. :)
 

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