Troop carirer transfer case split in

only for those smashed up against rocks:0 Actually never seen one split and have driven plenty of 75s and 79s seen plenty leak though (seals)

Thats a new one, I think its the same transfer case as used in the then 80 series if I'm not mistaken. (Stand to be corrected)

My understanding that its common for Toyota to have used largely same running gear through 75 / 80 series and 78-79 / 100 series today. So if the problem is prevalent in one model then normally would be seen in the other.

As Dave said, oil leaks in the older models but no split cases.

Maybe ask the question on here http://autos.groups.yahoo.com/group/troopyoz/

This the Troop Carrier Owners group.

what used to happen on earlier troopies (1980's) was that the idler shaft would wear until the gear teath started to touch the inside of the case, eventually a tooth would break off (due to reduced contact area) and then it would in turn get caught between the case and the remaining gear punching a hole in the case.
Sounds like what might have happened in your case.
I'd imagine the vehicle has some k's on it and would/could have been making a bit of a whine for a while?
If tojo transfers start to whine it is best to rebuild at that point as it would usually only require bearings and seals. Leave the noise for too long and major reconstruction or replacement is in order.

I have a 1996 troop carrier, if you can keep driving it as you say then then something is still intacted inside for it to keep working, does it sound crunchy like
things are falling to bits in there ???, or has damage been done from the outside.
these have a bash plate under them, is this bent and pushed against transfer case.
Where does the slit start and end exactly,