Transfer case hairline crack

[Raideljawn]

So got under the bronco the other day and noticed this hairline crack on the transfer case. I don’t see any source of impact underneath so can’t be from off roading, right ? I cleaned her up and monitored it for a week and no leaks- any clue how this could have happen? Should I be concerned ?

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[SS Bronco]

No skid plate, looks as if you hit it. Should be replaced soon before it falls apart.

 

[Raideljawn]

No skid plate, looks as if you hit it. Should be replaced soon before it falls apart.

Idk man, I’m in fl, so no real climbing , all I’ve been through is mud and sugars sand. I can only see a rock hitting it at that angle. Could it be caused by anything else ? Cause at this point I wonder if warranty will cover

 

[Doc TOC]

Maybe you hit it. But the force required to create a case crack would usually leave an impact scar or dent/impression. I am not seeing that.

It could also be surface cracks when the aluminum was cooling in the mold. The cracks may not actually go all the way through to the other side. It happens, but is usually caught in the casting plant. I had the casting surface cracks on a transmission case and a starter motor housing. Nothing every happened - no leaks, not moisture intrusion, no failures. Crack collected dirt, but that was it.

Have the dealer (or you can) take it off and inspect the inside. If the crack is all the way through, and you can't get it covered under warranty, ask the dealer if they can send it out for reconditioning (gets AL TIG welded inside) instead of paying for a new one. Just the inside needs closing up.

 

[Ford Motor Company]

So got under the bronco the other day and noticed this hairline crack on the transfer case. I don’t see any source of impact underneath so can’t be from off roading, right ? I cleaned her up and monitored it for a week and no leaks- any clue how this could have happen? Should I be concerned ?

Good morning! If you would like me to look into your concern on my end, please send over a DM with your VIN and Ford dealer info.

 

[Ducati1098]

To me it looks like that’s made from the casting, not hitting something. I’ve seen similar “cracks” on many transfer cases. I don’t think there’s anything to worry about.

 

[Imaginary Friend]

Looks like a casting flaw to me, not an actual crack.

 

[kr_1315]

That is not a crack. Wheel on!

 

[Fly by Nite]

To me it looks like that’s made from the casting, not hitting something. I’ve seen similar “cracks” on many transfer cases. I don’t think there’s anything to worry about.

Looks like a casting flaw to me, not an actual crack.

That's what I'm thinking too.... it's just a line in your case caused by a defect in the mold that got mirrored in your case. It may just be on the surface.
There are crack detection dyes avail, or maybe sand it down a bit to see if it just goes away. Likely nothing to worry about, but have your dealer look at it if you prefer.

 

[Onestepmore]

So got under the bronco the other day and noticed this hairline crack on the transfer case. I don’t see any source of impact underneath so can’t be from off roading, right ? I cleaned her up and monitored it for a week and no leaks- any clue how this could have happen? Should I be concerned ?

I have seen many casting cracks like this...it's not seeping which some castings can do...I would bring it to the dealers attention so it's on record but this kind of crack is common on castings and usually pose no structural integrity other than what you are showing. You've got a good eye...I'll look at mine tomorrow and if I have a similar crack I'll post it.

 

[BadlandsA51]

Looks like a surface flaw in the casting, they aren’t unusual. If it was a crack, it would be leaking. Also, I don’t see any scratches or gouges from hitting it on anything.

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