I've been collecting parts for a 3/4 ton conversion and 4 in lift for my '84 Blazer for the past year. This weekend was the date I have had set for a month to swap everything over. I have a set of 35x12.50 on 16.5s off a "Late '70s Ford" that someone gave me, a 14 bolt and D44 w/ 4.10 gears(new lube and fresh grease in the hubs), a 4 inch lift kit(blocks in the rear) and all new Rancho 5000s. The tires were a little wore, but I figured I could run on these for a couple weeks till I could afford a new set of '35s. Anyway, I used my truck to pull out a stuck forklift at work last week, popped it in 4 lo and hooked onto it with a chain, tugged the little bugger right out. That was like 3 or 4 days ago. This morning my transfer case just started gushing ATF and it was dry after about 15 minutes of sitting in the shop w/ a drip pan under it. I crawled under it, pulled the skid plate and discovered a hairline(thick hairs) crack about 2 inches long on the most lower part of the chain cover. WTF!!!??? No clunks, ran fine for 200 miles between the last time it was in 4 wheel and when it started leaking like a siv. What would cause that? I don't know if something in the case is broke or if it's just the case. Any ideas? I don't want to put any money into an NP208, but if it's just a crack, I'll pull it off and weld it up I guess. Any ideas? How much does an NP241 cost and how difficult would it be to swap out? I have a 700 R4. I want something tough that I can put good parts in and run w/ like 37.5s and 325 HP. Any suggestions? I'd go for a 205, but it seems like a tough swap for an OD, and I'm not swapping trannies now(just rebuilt it, $1500 later) So today I tore into it. Swapped in the 14 bolt, lifted the rear 4 inches w/ blocks and put new Rancho 5000 shocks on. The E brake lines on my 14 bolt are to short on the passenger side whats the best way to extend it? Also, what is the part number for the 1310 to 1350 U joint? The brakes lines hooked up with a little redneck engineering. So I went to put the 8 lug wheels on it I discovered they were not for a late '70s ford, but a late '90s ford and they have the metric 8x170mm bolt pattern!!!! SOB! Luckily I had some 8 bolt dodge rims w/ 265/70R17s on them laying around off my dad's truck, so those are on there now. Guess it's time for new wheels as well. Don't know if I should go 16s or 17s though. Just a crappy day, atleast I got the rear bolted in... got a date with the dana 44 tomorrow.