It looks to be the right one.
E-mail the seller to confirm if necessary.

 

Before I go about replacing it does anyone know what can cause this to happen?

 

The transfer case extension didn't just decide to crack.

Do you drive off road? Aggressively? Have you hit a curb very hard or done something that would transfer shock to the transfer case through the drive shafts? Were all the bolts tight? Was one too tight or loose?

??????

 

In this pic you can see where the big chunk came out.

In this one you might can see the crack that is a little bit above the bolts.

Also I do occasionally go off roading but I havnt in a while. Just recently though my tires have started cupping in the front because I havent been rotating them like I should. So this has caused some really bad vibration throughout the entire truck. So what I think is that the crack had been started a long time ago from the previous owner but just wasnt big enough to cause a leak. Then when the vibration on the tires started it cause the crack to get bigger and eventually fail. But then again idk because could a crack like this cause a vibration? Also could this cause the clunk that I have when I pull away from a stop?

 

I figured I would go ahead a change out the transmission mount too since it has probly never been changed. So to do it can I just unbolt the mount and jack up the tranmission a little or will I have to remove the cross member?

 

Ok well the transmission extension was way worse that what I thought. The whole thing was cracked. Im surprised that it didnt mess any thing else up. Here is the first pic. This peice fell off right after I took the transfer case off.

Here is another picture of it all out and in peices on the ground.

It is crazy how it was able to crack that bad. When I got under there the skid plate was bent up and touching the cross member. So I guess I hit somthing with out noticing it and the force of the skid plate hitting the crossmember was just enough to break the housing but not bend the cross member.

 

You would have to nail the dog shit outta something to bend that trans corssmember and the skid plate. I bet the PO managed to whack the transfer case off of something. It also looks like that tcase has been removed before looking at the rtv on the seal surface.

 

Yeah the PO did not take care of this Bronco at all. He probly never even changed the oil. Someone has already taken the transfer case off like you were saying. I know this not only because of the rtv on it but also because there was a broken bolt that goes from the extension housing to the transfer case ,and I guess who ever worked on it decided they didnt want to take the time to replace the broken bolt.

 

Usually a out of balance driveshaft will break the adapter like that. Ask me how I know.

As far as that fitting. I believe there are two styles for the E40D. You might want better pics. The lengths and bolt patterns will be the same. I think there's different bosses on the side.

 

Usually a out of balance driveshaft will break the adapter like that. Ask me how I know.

Actually 3 out of 4 bolts on the driveshaft on the transmission side were finger tight. So that also could have caused it to crack like your saying. It is also most likely the reason for the vibration my truck had at about 30mph. I havnt been able to drive it yet because I need to get a fluid pump cause a funnel is to hard to use to fill the transfer case.

 

I got everything back together and it drives good. But now there is a leak from some where and its not from the extension housing. It looks like it is coming from the transfer case where the two halfs are bolted together. I dont know why it would start leaking now though because it wasnt before i took it off.

 

Now my u joints are bad and they are causing a loud squeek noise. So I guess the reason my extension housing failed was because of a combanation of the impact from the skid plate and my worn u joints. So once again my bronco is just siting in the front yard waiting to get fixed. Also I looked more at the leak on the transfer case and it is from the transfer case halfs. I think what happend is that I cleaned up the transfer case when i took it off. I guess all the dirt that was on it was keeping it from leaking. So now I got to eventually take the tranfer case back off and fix it. It is a never ending thing on this bronco. Just one thing after another.

 

Yeah, any other 16-year-old machine would be operating perfectly with no maintenance.

Haha yeah that would be the case in less I was driving it. Then it would decide to break.

 

Glad I found this thread, same issue with son's Bronco. He said his happened while driving down the road and he reached down to grab a CD case and accidentally bumped the shifter from 2h to 4h while driving 50mph. Said it made a noise but continued to drive another 3 miles to GF house where he called me. I'm guessing he pumped all the transfluid out the back and trans is burnt up. Gonna dig into it this weekend. Where is the best place to get this extension. Thanks in advance guys.

 

I dont believe shifting from 2 to 4 would break that adapter. I've done that lots of times. If he broke the adapter, the tranny fluid will not drain out. I've bought those adapters on ebay.