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4R100 Broken Case

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We just had a 4R100 bolted to a 7.3L come through with the case split in two at the converter housing across the fluid pump area. The engine vibrated badly but the trans still worked and the truck was still drivable. Long story short the torque converter came apart internally. I have never seen that. I could pick it up off of the bench, shake it and feel a heavy thump

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I don't recall the year as I was not working on it but I think you are referring to the noisy converter TSB. I did not mention that this was a Ford reman transmission and converter but it was and the guy was lucky as hell as the warranty on the unit ended within days of the failure.  

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Had a buddy shop owner that had a Chevy box truck that had broken the case through the bellhousing several times. Being the curious type I went to look at it...the two-piece driveshaft was splined out-of-phase...DOH! :facepalm:  

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Funny you mention that - Hot Line told us to check for u-joints which were in fact new but the converter was definitely the problem. Until now I never thought a driveshaft could do that to the front end of a trans but I guess it can. I would think the rear of the trans would be more likely...

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I've seen 3 transfer cases completely destroyed in the past year and a half.  They were all on vehicles that were being driven in 2wd with the front hubs engaged.  The DC joint on the front shaft would fail, then destroy the transfer case from the vibrations. 

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I had a pile of 5 front shaft as 1 fleet instructed their drivers to keep the hubs locked in all the time. Only 1 destroyed the t-case. I unlocked the hubs every Time I saw 1 of these trucks. I could unlock them, but the drivers couldn't.

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We had a f-350 break the case across the top, Cause by the front shaft u-joint worn and vibrating.

We see those on a regular basis, mostly from the front hub seals failing and the front hubs stay locked in. They get up to highway speeds and BOOM. What a mess. We have 2 fleets that stock a few of their own t-cases and send them down with the trucks.

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 When I was at NVH classroom course, on the course before mine, the instructor broke the extension housing off of a trans by introducing a driveshaft vibration. He wanted to make is bad enough that the EVA would easily pick it up. For the next class the induced vibration was much less severe.

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