So here is the update! My master cylinder went out and bled into the booster pump. It was a mess, $1000 fix at dealer, Due to all the rubbing that was going on and intense heat that was created, my rotors now need too be replaced due to the "hot spots". The dealer found this potential solution on their own GM-Dealer Bulletin Board. The message board identified the solution and problem in the VIN number due to parts and manufacturer dates and location. Not big enough to be a recall but isolated enough to identify. All $$$$$ came out of my pocket. My dealer did the best they could to save me money since we were spending money prevoiusly to solve the issue. didnt charge me for work that was redone.
Finally, after 10 years I have found a forum that matches my issues. This should be a borderline recall issue. It has happened to me while driving, it has happened to me after the truck sits!! This has been the one problem that has haunted my '05 Sierra from day one. Just started happening again a week ago and my truck will not stay engaged in 2hi. Luckily it is defaulting to Auto 4wd. Frustrating beyond control!!!
'05 Sierra Z71, I've dealt with some part of the 4wd selector system, first couple were warranty, last two out of my pocket. As of yesterday, it won't stay in 2hi. It primarily stays in Auto 4wd. This has been my biggest and consistent issue with my truck. Don't always need the 4wd, but when I do it makes life really easy. Next truck won't be a 4wd. Pissed off beyond it all!!!
So I am dealing with this right now myslef. Not trying to mess with brakes at all. Asked the advice of buddies who race and who have been working on cars their entire life, they came up with contaminated fluid or master cylinder is going out or misadjusted with thermal exspansion going on!!! Fluid was bad, really bad, so I went with the system flush...that helped but didnt stop it. Going with the master cylinder next.....I'm bleeding money!!! But with all the other forums that I've looked into, it always seemed to go back to the master cylinder. Good Luck!!