Wardster

I found this out after I actually spoke to the mechanic at the dealership. They told me that it would not hurt anything since I already had the AutoTrak II in the t-case, so I did not bother to switch it out. -Wardster

I filled the hole with JB Weld when I got home last night after prepping the area like you described. If felt like it set up really well when I checked it this morning, so I will give it a test run tonight. I will pick up four quarts of Auto-Trak II from the dealership, so I can change it a couple more times to make sure its clean. I am hopeful that this will solve the problem. -Wardster

I just spoke to our general superintendent and he said this was pretty common on all of the trucks we have (first I heard about it). He said the same thing about the JB Weld, but he said that he also used a sheet metal screw with a rubber washer to accomplish the same thing. I will start with the screw and use the JB weld if the screw does not work. When you drained your fluid the first time, was there alot of fluid in the t-case? -Wardster

That is exactly where it is. I have never used JB Weld, so help me out with the specific type (if any) to use. The reason I ask is the guy with the rebuilt t-case has not called me back yet, so I may try the band-aid for awhile before spending a grand. Especially considering the fact that you have not had any issue with it after a year. On another note, I see you are from Summersville, WV. I am currently managing the construction of the new bridge across Summersville Lake (Rt 39) right now. I could send you a couple of pictures if I had your email. -Wardster

I visited there yesterday and have already spoken to Eric (the resident D-max/Alli genius) about a replacement this morning. He has one rebuilt t-case for $1K, so I am going to move forward with the purchase. He does not have the modified t-case tested yet, but he is hoping to have the R&D finished and available for purchase later. It just sucks that this problem goes back to 2001 and has not been fixed by GM yet (Eric said he replaced an '05 t-case last week). Apparently New Venture is the manufacturer of the t-case, so I am going to snoop around for info on them. To be honest with you, I am suprised that I had never heard about this before. -Wardster

My earlier post about the leak at my transfer case has been diagnosed as a small hole. Apparently, there is an anti-rattle clip located inside the transfer case that breaks and causes the hole to form from the inside out. The scary thing about it is that there is no way to inspect it unless you tear apart the transfer case or it starts leaking. I had no idea that I had a hole in the transfer case, so I continued to drive the truck even after I noticed the drips on the floor last week. Last night, I put the truck on ramps in my garage and proceeded to drain the transfer case. According to my dealership, the case holds two quarts of Auto-Trak II that I purchased and I had in hand. I removed the plug and held a msaon jar underneath it and collected about an inch of fluid (a couple ounces). I put the plug back in, then put both quarts in and replaced the fill plug. Drove the truck off the ramps and out to the end of my lane and back (~1200ft) then put the truck back on the ramps. When I got out, I noticed the trail of blue dots that originated from the t-case. When I got underneath, I discovered the hole. I am not really sure what to do now, but I did discuss this issue with my service guy while at the dealership yesterday. He told me that there was nothing they could do about it since my extended warranty expired 3K miles ago (currently @103.6K), but he would make contact with the regional rep to see if GM is doing anything about it. I left the truck on the ramps and the 4x4 still works, so I hope that a new cover and clip will do the trick. Based on the research I did, this problem is turning into an epidemic, so GM may be forced to do a recall but I am not going to hold my breath and I cannot afford to wait on them to do something. So.....who else has had this problem or was aware of it and what were your experiences? How hard is it to remove the t-case? Is it as simple as dropping both driveshafts? Let me know. I have a couple of pictures that detail the problem, but I am not sure how to post them. I could send them to someone who could though. Thanks in advance. -Wardster

You reminded me. I can't use the line "the house payment sits in the garage anymore" as I paid Blue off in January and managed to save up some cash to get a place built. I actually own the apartment building I live in, so the truck is the only payment I have to make. I could actually buy a pretty big house for the same money, but I am content with where I am.

Circleville.....30 minutes south of Columbus on US 23. -Wardster