It is not safe to drive with a broken transfer case. If your transfer case is showing signs of damage, you should have it replaced immediately to avoid transmission damage or issues with your axles and driveshafts.
Your car will continue running with a damaged transfer case, but that doesn’t mean you should keep driving if yours is showing signs of deterioration.
A faulty transfer case can lead to transmission problems and driving issues, which could result in expensive repairs throughout your vehicle. In this article, our car repair
experts will explore how long you can go without replacing your broken transfer case. 
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Is it safe to drive with a broken transfer case?
Technically, you can drive with a broken transfer case, but it's recommended that you take it in for repairs or a replacement as soon as you notice issues. The longer you wait to fix your transfer case, the greater your risk of harming other expensive car parts, like your transmission or axles.
Transfer cases are typically found in all-wheel or four-wheel drive vehicles, both manual or automatic. Your vehicle’s transfer case is a part of the drivetrain system and is responsible for taking power from the engine and directing it towards the front and rear wheels using the axles. Transfer cases support drive performance in snowy, icy, or rainy conditions, or when off-roading or driving on steep inclines.
Since the transfer case (TC) is directly connected to the transmission, axles, and downshafts, these parts are all at risk of damage if something goes wrong with the TC. With this said, if you notice issues with your all-wheel or four-wheel drive system, unusual noises from beneath your vehicle, or difficulty shifting gears, you should take your vehicle to a mechanic for a transfer case assessment.
How long can you go without changing your transfer case?
Transfer cases can become contaminated over time from carbon buildup, so it's recommended that you change your transfer case fluid every 30,000 miles or every three to five years. If you frequently use four-wheel or all-wheel drive for towing, expect to change it more frequently.
In some cases, drivers never have to change their transfer case. Depending on your driving habits, your transfer case may stay in good shape until you retire your car. Generally speaking, transfer cases last anywhere between 150,000 to 200,000 miles, which exceeds the lifespan of some vehicles.
Remember, the sooner you replace your broken transfer case, the less likely your vehicle will experience excessive damage to other vital parts.
Can a bad transfer case cause transmission damage?
Yes, a bad transfer case can definitely cause transmission damage!
Transfer cases are highly important to the overall function of your all-wheel or four-wheel drive systems, and they are directly connected to your transmission, driveshafts, and axles. If your transfer case completely fails, you could damage your transmission, which would require further (and costly) repairs!
How to tell if your transfer case is broken
One of the first signs of a bad transfer case is difficulty changing gears or issues with your four-wheel or all-wheel drive system.
Watch out for these symptoms of a faulty transfer case:
Difficulty shifting gears: If changing gears
becomes harder than usual in a manual or automatic vehicle, your transfer case could be to blame Complete lack of shifting: If your gears fail to shift, you should have your transfer case checked out by a mechanic
Unusual sounds: Grinding, chattering, or clicking noises from beneath your vehicle could be due to a faulty transfer case
Spontaneous disengagement or engagement of drive modes: If your vehicle suddenly switches in or out of four-wheel drive, there may be issues with your transfer case
Leaking transfer case fluid: If you notice fluid leaking from your transfer case, you should refrain from driving your vehicle and have it towed to a mechanic
Burning smell: If your transfer case is low in fluids, there will be increased friction inside of the case, which could create a burning smell
Check engine light or service 4WD light illuminates: If you notice the check engine light or service four-wheel light on your dashboard, a bad transfer case could be the culprit
If you have an OBD-II scanner, you can use it to detect trouble codes associated with your vehicle’s transmission, which could indicate problems with your transfer case if it returns a CO306 code.
How much does a transfer case replacement cost?
If your transfer case can be repaired, you’ll be looking at costs to replace damaged parts or to add fresh fluid. If it needs to be replaced, you’ll be looking at much higher costs to source and install a manufactured TC. This can cost anywhere between $2,500 and $3,000 depending on the severity of the issue for parts and labor.
Yes, getting a new transfer case or replacing parts of your old one will be expensive, but it’s not as pricey as letting the issue get worse and having to replace your entire transmission, axles, or driveshafts.
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