Thanks for all the help in advance!
I have been thinking... after raising my Eagle up a bit, I have had 2 transfer cases come apart inside. Maybe coincidence, maybe not.
The first transfer case was the one that was in it when I bought it. The viscous coupler cracked, pieces came off, got between the chain and the case, and the case split.
The second case was pulled from a donor car and I just put it in mine with no rebuilding. It seemed to operate OK bench testing it. Less than 200 miles later, POP! This case split but this time I believe the chain came apart. I haven't opened the case to look at all of what happened.
For the lift... I put new springs on the front AND the 1" spacers. The rear has the new leafs, add a leaf, and some shock stud extenders. Everyone says New springs will give almost 2 inches of lift and the 1" spacers will give almost 2 inches of lift also. They did. When I put both on the front, I measured before and after and got 3.5" IIRC.
This may be a coincidence but would it be likely that too much angle on the CV shafts would put too much stress on the case, causing it to fail? Or... would it be a lot more likely to just cause problems for the CV shafts. There is still some travel left on the front A arms before they hit the frame so it isn't maxed out but it is up there.
I want to have new upper arms made that push the front up a couple inches while using original springs (to keep the ride the same) so I can do the 2" spacer between the frame and engine crossbar as well as trans crossbar and frame (shorter than the front though).
The axles handle 3" barely okay (on road) S10 4x4 front axles will give you a little more length to account for the extension of teh shafts needed for the change in angle.
Probably just a coincindence. I'm sure your cv's are at harsh angles with 3.5" They won't live long, but shouldn't have had any effect on t-case. Is this a full time car 119 or a part time car 129? Was it in 4wd when the failures occured?
3.5" is with the replacement springs (2" back up to stock) then another 1.5" over with the coil spring spacer.
I can't remember if it was in 4wd when the failures happened. I think it was one of the times but I am not sure.
***There is a 128 in there now. I know many have said it isn't as good of a case but I wanted to make sure there wasn't a viscous coupler in there to give me any problems with this case.
With the 2 cases that have gone out in it, it makes me a bit worried to drive it because getting it towed when you had plans to go/be somewhere really stinks.
That's why I wouldn't mind a NP228. If you put it in low range, you're locked front and rear together.