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Do you still have your old t138? If so maybe open up the sprag section of it and find out what went wrong. User Simp5782 has welded up a sprag on a t138 before, sure he would be willing to guide you through the process if you are interested. Much cheaper than buying a different tcase and...

Gotta clarify a few things on your tcase. The T138 (stock for the m809 series) is not an air shift, its a sprag. It uses air to engage the sprag in either forward or reverse, and the sprag determines when to engage the front axle. It's known to be a very strong tcase. If you want 4x6...

You can get the T-1138 tcase from the m939 series for about $400 nowadays if you want better highway gearing. How are you breaking the T-138 so often?