Anyone break the 4l80e to transfer case coupler before?
 

I've had a small transmission leak for a couple of months (I've only owned my 05 2500hd for 5 months). Always a 1-2" dia drop puddle after driving, until recently larger puddles were present. I finally got off my ass today and looked into replacing the extension housing/adaptor gaskets (which I had). Upon further review it looks like the transfer case has an amazing amount of flexible up/down movement from what I can only guess is the housing adaptor breakage. The output side of the trans is solid, but it looks like the adaptor moves freely 2-3mm up/downward with assistance. My trucks on 35's with 6" of lift, so I'm guessing the added stress and possible bad u-joint (maybe but doubtful) may have caused this. Anyone else experience this?

I think kbracing broke his.

Any chance of just having loose bolts?

Bolts, or at least the 4 I tried are all tight

That's not good. Time to get dirty.

Great time to dump some more money into the new toy:bang:

Yeaaaaaaaa it was worse than I thought.:punch:

Mine broke when my driveshaft exploded... My transfercase was just sitting in the skid plate at 130 mph lol

ouch, i bet there was alot of cleaning up to do on that occurance

I've broke two on the 60/65 setup. My 80e setup is freaking steel I think. It's been a while since I messed with it but I swear it was not aluminum.