Hi all,
I was wondering if anyone knows a way to bullet proof these annoying transfer cases on a 2008 V8 XC90.
I've got a big job ahead of me pulling it out and wanted to know any tips or tricks to make the new one last as long as possible.
Thanks in advance 
@iceton1975 are the later model diesel ones any stronger?
Carroll Smith in Engineer To Win was a big fan of shot peening highly-stressed parts like gears. But you need somebody really good to do it, like a shop that's certified to do aircraft work.
If (as Timbo suggests) the newer and later Dweasel angle gears are stronger, it might be worth getting one and getting the gearset professionally shot peened, then do regular lube changes to keep it bulletproof - none of this Sealed For Life nonsense.
Major Ledfoot does this require opening the transfer case ?
Lamar - Yes. It would need to be fully dismantled, then the internal components are shot peened, then the unit is reassembled.
By no means cheap, but it should be bulletproof with fluid changes at sensible intervals.
