So here's why I need a new transfer case. The np231 just won't hold up to the abuse. The first problem I had was that I cracked the front case top to bottom right beside the front output. So, I welded it up thinking that it was a fluke.
In the mean time I had replaced it with a different front case. On my next outing, I did it again to the new case......... no longer a fluke. So, before I installed the one I had previously welded, I added some aluminum gussetts. So far, it's held up.
But next, I broke the front output shaft.
Time for a new Atlas when the budget allows.