T-cases are usually very strong and can handle big engines up to 15% than their original engines, but some T-cases are just like making the front tires move but they don't produce enough torque. For extreme offloading you need a huge engine and a T-case that can handle the torque coming out of that beast without breaking or loosing its gear teeth and multiply the torque( t-cases are also known as multipliers). So if you upgrade your engine and add more horsepower you will definitely need a new t-case.Some of the factors you should keep in mind when swapping one:
1. if you are buying a T-case from a junk yard which are usually very cheap, you may need to repair it alot.
2. Make sure its compatible with your transmission, or the adapter kits are available and the mounting plates and the output shaft may vary in size.
3. Since T-cases are usually of different sizes and vary in length. Depending on the size of the T-case you may have to shorten or lengthen your front and rear drive shafts. So before pulling any stunt confer it with your local mechanic.
4. I would prefer T-case made of cast iron, don't opt for the latest aluminum and alloy made T-cases they are light on gas but wont give you the performance of a high end offloading. But if you can get hands on a hummer T-case which is made of alloys then go for it provided it fits in your truck :P
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