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Thread: TCase issues/potentially solved

  1. #1
    Living the WAYALIFE Ddays's Avatar
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    TCase issues/potentially solved

    So my Tcase issues are fairly common I guess. Two cracked cases are enough for a lifetime. I could never really figure out why this happened, especially the grenaded one.
    I was at the shop checking on the progress of the axle install today and happened to look at the Tcase that just got taken out. Matt, the mechanic showed me something that I'm now pretty sure has been the issue all along.
    So on the Tcase drive flange, the nut that holds it on has a wide flange on it. An o-ring gets compressed in a recess and that seals off the fluid.

    20200520_170610_resized.jpg
    20200520_170618_resized.jpg
    20200520_170641_resized.jpg


    But the nuts that were holding the flanges onto the tcase weren't wide enough to stay up out of the recess - instead they fit inside the recess and compressed the oring seal onto the splined shaft AND NEVER SEATED AGAINST ANY METAL. It always had a cushion between fully seating that more than likely allowed the flanges to wobble slightly and created a vibration that caused the cases to fail.

    See how it doesn't sit up on the recess, rather it fits inside it.

    20200520_170628_resized.jpg


    So even though I had both shafts balanced (twice) new Ujoints, caster set at 6* etc, etc, the shafts must have been wobbling enough to cause failure. The new Rubi case has nuts with larger shoulders that sit on top of the flange instead of inside it. I really hope this solves the issue. Well, having lockout hubs helps too, but still. Check your nuts!
    https://wayalife.com/showthread.php/...build-of-Gruff

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  2. #2
    Nothing but a Thing 19YJ94's Avatar
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    So where did the wrong nut come in to play? How did it get put on in the first place?

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  3. #3
    Living the WAYALIFE Ddays's Avatar
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    Quote Originally Posted by 19YJ94 View Post
    So where did the wrong nut come in to play? How did it get put on in the first place?

    Sent from my SM-S506DL using WAYALIFE mobile app
    That's the mystery at the moment. Both the front & rear flanges had them installed. I thought possibly I did it but I looked in my spares because I keep all of that shit just in case & they're not anywhere to be found.
    https://wayalife.com/showthread.php/...build-of-Gruff

    Gruff 2014 JKU Moneypit
    Badger 2019 JLUR waiting for scraps

  4. #4
    Knows a Thing or Two Elroy231's Avatar
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    Glad you found that!! Damn that has cost you some coin chasing that down. Not to mention the heart ache. Smooth rides ahead.

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  5. #5
    Addict wjtstudios's Avatar
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    Well at least you have an answer


    2015 JKUR AEV JK350
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  6. #6
    Old Timer jdofmemi's Avatar
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    Glad you found a likely suspect.

    Hopefully that means your troubles are over.

    Where is this located. It's hard to tell from the close up picture

  7. #7
    Addict JKbrick's Avatar
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    Good catch Jerry, not sure if your supposed to but I reused the original nut and oring, put a bunch of rtv on the oring and red locktite on the shaft threads. Better get some bigger nuts buddy


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  8. #8
    Living the WAYALIFE Ddays's Avatar
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    Quote Originally Posted by jdofmemi View Post
    Glad you found a likely suspect.

    Hopefully that means your troubles are over.

    Where is this located. It's hard to tell from the close up picture
    These are the nuts that hold the drive flanges/yokes onto the Tcase output shafts, both front and rear.

    s-l1600.jpg
    https://wayalife.com/showthread.php/...build-of-Gruff

    Gruff 2014 JKU Moneypit
    Badger 2019 JLUR waiting for scraps

  9. #9
    Old Timer jdofmemi's Avatar
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    That makes sense. Thanks

  10. #10
    Addict JKbrick's Avatar
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    The more I look at the picture the only thing holding your yokes on was the compression of the orings? yikes


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