A little update: Since this incident, which may or may not have been caused by an impact to the transfer case (The skid plate was bent up touching the case), I decided to fab up my own skid plate.
One of the challenges here is there is no place behind the transfer case to support the back end of a skid plate. Any others on the market just angle off to the side like the stock ford one, making them weak.
So heres what i did. I built another cross member from 1.75" DOM i had left over from my chase rack build. I cut side brackets on our CNC out of 3/16 steel to mount it. On the left it mounts to the stock holes, on the right it mounts to holes in the frame that were unused.
Then I just CNC'd a slab of 1/4" steel about 20" x 19 (Yes, im paranoid about damaging that t case again) that spans from the X member in front of the case to my X member behind the case. I got the plate as high up as possible, cut a hole for the T case then welded up a kind of recess for the T case.
Ill post pics as soon as Im done...should be done tomorrow. Heck maybe ill sell these if anyone's interested.
We have *A LOT* of rocks here in Colorado, so i needed something that could basically support the entire weight of the truck without bending into the case. The slab of 1/4" weighs about 33lbs....but this is a small price to pay for the several thousand dollar T case and replacement. I thought of it this way...its the lowest hanging component on the truck, so im going to use the thickest material under it since its the most likely to get hit.
That sucker (T-Case) hangs so low, I Can't believe there wasnt a better design that could have been used to get it high up like the trans...
--John