Is the problem that the shaft splines are not aligning? Is it possible to rotate the TCase and align the splines as you mate them? It would take only a few degrees of rotation, if the case...

I can't see ANY fluid 'malfunction / heat buildup', that will blow a hole in the case???

ENgine problem sounds like a different problem. How it could cause a mechanical failure in the TCase is strange.........

 

It is not bolting it up it is getting the transfer case to slide on to the transmission spline. The case is exactly the same as the one that came out. I pulled it off an identical car and matched the part #

 

I got it on. Just had to drop the transmission an inch or so and it went right in. The car now drives but the engine runs like crap. up until the t-case failure it ran spectacular. My theory is that the t-case was dry or nearly dry. 2000 straight miles of interstate speeds caused the internals of transfer case to explode. When that happened ( at speed) the car dropped itself into a low gear and the revs shot up causing stress on the engine and possibly engine problems. I will be looking at that tomorrow. If anyone has any ideas on where to look I am all ears.

 

A couple of problems will make PCM enter default / limp home mode.

Disconnect the battery, start the engine to Closed Loop (warm motor), and see how it idles and revs. NOT drives...

A warm motor defaulte to Open Loop will choke and bog down.