i have a 2005 xlt 4x4. about a month ago i was traveling through tennessee about 70mph when i felt something slam underneath my feet. when i got out to look i realized that the front driveshaft broke loose at the u-joint, flew up busted the fuel line and a hole in my transfer case about an inch and a half big. I just now got the money to start to fix it but my truck is outside of nashville in erin tn so i have to drive down this weekend to work on it. i bought a new fuel line for 160$ and i got a used t-case thats in pretty good condition. i didnt get a new ujoint yet to fix the drive shaft but i was wondering a few things....

1. can i just take the drive shaft completely off for now just to drive it up here and fix it?

2. should i put the t-case on down there or yall think i can drive it up here with that hole in it? or does it share fluids with the transmission? i just dont know if i will lose all my tranny fluid.

3. is it that hard to put on the tcase and if not, what all tools should i need and new gaskets or anything else?

please someone respond asap i have to head out tomorrow evening cause its my only break from work..thanks in advance

 

also if anyone is in that area and wants to make some money to give me a hand saturday holler at me

 

You can drive without the front drive shaft but im not sure about the others since i dont have a 4x4

 

my guess is that a full socket and wrench set would get you by, even taking the trans out doesnt require anything special, along with random pliers and screwdrivers, hammers... but mainly just a good set of some basic tools

make sure to bring a fuel line tool too

 

yeah i just went and got one of those today, i didnt realize i would need that till i picked up the fuel line, i think its a spring clamp or something. thanks for the fast response.

 

How bad was the fuel line? They have compression couplings that fit, take 5/16" for fuel, 3/8" for vapor. Might save some time if they fit if it's not a long section damaged .... I'm guessing steel line up near TC.

TC does not share lube with transmission, but it needs lube in it. How big of a hole and where is the hole? If I was desperate to get her home, I might try a patch made of thin wall aluminum bent to fit contours and epoxy for sealant and maybe a few screws. Just depends on hole and placement? Certainly any patch would need to contain some lube.

If in question, if I had my doubts of a patch getting me home ... and if I had time, I'ld try put spare TC in though.

I'ld remove the front drive shaft altogether until I got her home.

There's a lot of fixes available for fuel lines though. I had to repair a section up over the gas tank eaten into by squirrels .... could not see paying $265 as it's not warrantied against teeth, and so I repaired the high pressure side (5/16) with splices and copper and the vapor side with splices and 3/8 FI hose.

Sorry, not near Erin, Tn. That's just south of Ft Campbell I think.

Good Luck!

 

if you have a spare tc, and its not too far of a drive, i would just drive with the hole in the tc

 

Yeah, sure enough .... if not too far .... and if he kept speed down some. It'll have a better chance of making it at 45-55 than at 70 mph. If he's got the case with him and it starts to look like he ain't gonna make it, then he could try to find a place to do a R&R.

I reread his post, he said it was a hole about 1-1/5 inch? One of those rubber expasion plugs might fill most of the hole and then pack epoxy or JB Quick Weld around it.

Not sure where he's at but truck look's to be about 30-35 miles drive south of Ft Campbell where there's a lot of service men & women.

 

1) yes
2) no, ideally needs to be fixed before driving.
3) hard, ehh not really just more time consuming. now i'm not sure how the electrics are wired. you most likely will need a puller, mine wouldn't budge on my toyota's. yes you will need a gasket, you can probably make your own but if you have time to order one i would go ahead. do it right so you only have to do it once. need a tranny jack, TC aren't light especially when you will be right below it. bring a wide variety of sockets, open end wreches and a torque wrench, make sure to use factory torque specs to prevent issues. rear DS will have to be pulled to get the TC off. not a job to do by yourself in the middle of no where thats for sure.

didn't see how far you said you live from nashville, if close you could always try a half assed fix on it and repair it correctly at home

 

i might try and plug the t case hole and j-b weld it. to replace it is a time consuming job. but not that bad. +1 on the drive shaft pulling. take it off. u could rent a 2 wheel car puller and put it on backwards. that would work i would think.