Ok this thread may not apply too well to all of the USA members as I believe from the 7 onwards the transfer case is a bit beefier, as well as the front diff itself. However, I ask for your advice regardless because I need it!

Here is the story, I have a Evo 6, Magnus 2.4, HTA GT35R, Autronic SM4 tuned by Mark Shead, and a bunch of other bits. I'm real happy with the car on pump and on race its really very scary and so I love it.

Now the problem is, I keep breaking transfer cases. Here is some pics of the carnage and I'm hoping maybe someone can recommend something for me. Keep in mind the Evo 7/8/9 have different front diffs and transfer cases to the Evo 6.

All four busted transfer cases... one is not pictured as it is over to the left stuck to an old driveshaft! lol



Now here are two pics of the most recent failures... as you can see it is the same thing breaking:



And the other:



Before these two, I broke the output shaft from the gearbox:



And finally, the first transfer case failure I had was bit different. I had not that many mods yet, but had driven the car hard for like 4 years with lots of launches, and I guess it finally gave up. It was working but would click big time every 20 or 30 ft or so. Here is what it looked like:



The last one I think is not too important as it lasted me 4 years. The other 3 lasted me less then a couple months each.

Any help greatly appreciated.

At this point I'm concerned I can never run race fuel again!

 

Dang! That's some serious carnage. I'm stumped, man. Someone on here will know how to help. Bump for an Evo bro

 

Look up Shep or TRE. They are the transmission/transfer case gods here in the States. Also, a while back i read about an Evo VI equipped with a JUN transfer case so you can probably check into that too. But damn! You must really drive your car.

 

Sheptrans.com, Teamrip.com. Look them up bro!

 

For sure call Shep. He is the man.

 

May want to ask about cryo treatments and shotpeening...to see if you can't strengthen some of those weak areas..

 

i have a shep

 

I did call Shep... problem is not a lot of options for the six. I haven't sent him the pics yet so will do that now and see what he says.

I'm really jealous of you later evo owners as apparently you can get a Quaife front diff with LIFETIME WARRANTY!

 

Holy carnage!!!! U have way too much power for what seems to be stock transfer cases . If this is the case u should really look into have a built TC.

 

I have the fix for evo 4,5,6 transfer cases..

We had custom parts made for these cases.
We broke a ****load of them too on our EVO5.

Contact Jigga for details...

 

Maybe put a less aggressive clutch on the car. Also consider toning down your launch. My friend put a Exedy Twin HD in his 370whp Evo IX MR and got a broken hollow shaft just like you've got there, along with a broken center diff, and broken ring gear.

 

Did you all redesign the hollow shaft or the center diff gears?

 

Take a layer off son!!

 

Thats easy

http://www.nolimitmotorsport.com/prod/QDH11B

If you crack this one you will get a replacement right away from the company. The give it a lifetime war.

 

mr jigga is pm'd