Transmission/transfer case adapter

[Hughiam]

Ive got a 2004 GMC 2500HD 4wd. There is a factory flaw in the transfer case, a spring inside the case rubs on the wall and eventually wears a hole in the case.

That happened to me in Nov of 2009. So I had the transfercase and adapter between the transmission replaced as it had a crack in it.

Since then I have replaced 6 more. 5 of them were warranteed, but the last one was on my dime. Ive had the mounts replaced, driveshaft etc. but I get about 6 weeks out of it and it starts leaking again.

This is a pretty soft duty truck with 145,000 miles on it. It seems every time I put it in 4wd or pull a trailer it breaks. I don't beat the truck , but one hill at my lease required 4wd for about 100 yards.

My trailer is a 12 foot enclosed that I use to deliver taxidermy mounts so its not too heavy.

My mechanic said he googled the problem and it does happen, but apparently Im setting a record. Anyone have any insight.?

Were going to try and warranty the transfercase this week to see if that stops it.

Thanks

[Johnny Dangerr]

Yea it is a problem. I have sold a bunch of used units. I think I heard the guys at Circle D in Houston have a permanent fix. Give them a call: 713-895-7019

[Hughiam]

Thanks Ill pass it along

[flinch]

Go to merchant-automotive.com. Scroll down to the transfer case pump upgrade kit priced at $99.00. That will fix the problem. I have had one in my 04 2500hd for 5 years with no more problems. Also on dieselplace.com there is a catagory in the forum for do it yourself fixs on different problems that will give you detailed instructions how to install this part if you have even just a minimal amount of mech skill if you want.

[Mike D]

Dang Chevys!

Couldn't resist.

[HELLRAZOR]

1 out 50000 chevys not bad........chevy rocks

[05 gray ghost]

very common problem for 2001-2008?. The transfer case has a metal clip in one of the notches that the oil pump sits in. My first broke at 145,000 miles and the second one at 222,000 miles. Look on duramaxdiesel.com or dieselplace.com forums they both have a lot of info on the infamous transfer case oil pump rub in the transmission sections.

There are 3 fixes that i know of, one is metal that you slide in before you install the pump, one in a pump shell that has wider contact areas, one is a aluminum transfer case housing instead of magnesium.