4x Problem

[zorrro]

Hi All,

 

My father drives a 2002 Duramax Alli Sierra 2500HD. It quit engaging 4wd and he took it to the dealer. The dealer found a hole in the top of the transfer case. The technician said, he had seen about 5 or 6 of these trucks do that. Apparently there is a pump in the transfer case that can rub a hole the housing? The truck has about 80K on it. The fix is (of course) a new T-Case and the price is steep. Anyone else seen this before? Know how involved a transfer case swap is on one of these?..............Thanks, Zorrro

[jake111]

Yes, it appears to be a common problem. There's a spring clip on the pump that wears through the case, creating a pinhole. I haven't experienced it, but have read about it on other forums. I sent you a private msg with links to pictures.

 

[on edit] Here's a link on this site:

http://www.gm-trucks.com/forums/index.php?...topic=48648&hl=

[Shaners]

If I rmember correctly, this happened to one of our members quite some time ago. He claimed he repaired it himself by carefully applying some JB Weld to the hole. I guess if the T-case is junk, it's worth trying a $5 fix before spending the big cash on a new T-case.

[slowpokebanshee]

there is no need to replace the t-case.....although not a common problem, I have seen it more than once, you can get the (back half) new from the dealer, if I remember it's about $300, and fairly simple to replace, if you are interested in the repair, e-mail me at :

[email protected], I can walk you through it so long as you have some general automotive knowledge.

[Burrito]

My transfer case developed a leak and lost most all of it's fluid and destroyed the internals and slip yoke. It was probably the same leak that your dad has. The shop basically told me it was a defect in the transfer case, and by the time I discovered it, too much damage had been done. The way I realized I had a problem was I was noticing a vibration in the floorboard of my backseat (right above the drive shaft). I took it in and they diagnosed it. I never new it was leaking because the leak was on top of the transfer case and would only lose fluid when pressure was inside the case, not when it's sitting in the driveway. It had less than a cup of fluid in the t-case when they drained it, and that looked like metal shavings and sludge. $2100 later, my truck was healed. I think the new t-case was around $900, the nickel plated slip yoke was $250, and most of the other charge was labor. Hope this helps.

[zorrro]

Thank you for all of the replies. The link by Jake111 was very informative. The internals have been wrecked in this case (now that's funny!) and the dealer price of $1800 seems to be the best deal out there? Doing it ourselves wouldn't be worth the $400 we would save. The dealer work comes with a 25K mi warranty. It's too bad it wasn't caught early. I'm planning on jumping under my own just to check before the same thing happens to me.............Thanks, Zorrro

[avanveen]

What happened to 'Burrito' is exactly what's happened to my truck...i'm taking the dealer to small claims court so does anyone know of any bulletin's or anything that GM has now issued on this problem that I could use to proove they knew it existed? Anything would be helpful, thanks,

[TEXASCHEVYOWNER]

What happened to 'Burrito' is exactly what's happened to my truck...i'm taking the dealer to small claims court so does anyone know of any bulletin's or anything that GM has now issued on this problem that I could use to proove they knew it existed? Anything would be helpful, thanks,

 

 

I have the document you are looking for, I could not find it on internet. It states 1998-2007 Light Duty and Utilities

 

Document ID#1962218

 

http://service.gm.com