2003 2500hd Transfer Case

kingsfisherman · December 15, 2007

2003 2500hd reg. cab 4x4, 88,000 mi.

transfer case seems to be kicking out of gear. It started about a couple of months ago with some slop in the drive train,thought it might be a u-joint so I had a friend whose a fleet mech look at it and he said there was some play in the slip yoke, last week when my wife was driving it got worse, it started to make a clicking sound when she let off the acccelerator which became a clunking noise and a loud whirling grinding noise while braking. So she pulled over and shifted the transfer case into 4 hi and it drove fine until she decellerated again to shift it out of 4hi and the process repeated itself even in 2hi. thanks for any help here.

ok went out and started the truck,while in park was able to shift t-case through all the gears no problem,then put it in drive.. still good ,then put in reverse it started the grinding and I shut down. then I put it back in park and restarted it and its fine until I go to shift back into drive it grinds for a second then it clunks in and is fine.

kingsfisherman · December 17, 2007

Ok was able to test drive the truck today. Had to shift the t-case into 4lo to get reverse, it also drives fine in 4lo. But when driving in 4hi I could hear it trying to kick out of gear,that was the clicking sound my wife was describing. also no reverse at all in hi range. So it appears that the problem is in the hi range side.

kingsfisherman · December 23, 2007

just before removing the t-case I drove the truck again and it drove both in 4hi and 4lo did do a little bit of clicking in 4hi, but it did'nt kick out.

gmtech4 · December 29, 2007

just before removing the t-case I drove the truck again and it drove both in 4hi and 4lo did do a little bit of clicking in 4hi, but it did'nt kick out.

how is the oil condition?,no reverse sounds a little odd,take it to a dealer,it may have to come out & apart,how is transmission oil ?may have to be scanned if electric shift.

kingsfisherman · December 30, 2007

just before removing the t-case I drove the truck again and it drove both in 4hi and 4lo did do a little bit of clicking in 4hi, but it did'nt kick out.

how is the oil condition?,no reverse sounds a little odd,take it to a dealer,it may have to come out & apart,how is transmission oil ?may have to be scanned if electric shift.

took it to a re-builder and cracked it open found the pump was gone couple of bearings, something to do with the shifter, anyway he also wondered about the fluid level. maybe the rear output seal went from the slip yoke going bad. should of known that the slip yoke could cause the seal to leak.but anyway shoulds get it back togather tommow. thanks for your help.