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Username Post: Empty Transfer Case?        (Topic#366685)
JLDT 
Member
Posts: 274
JLDT
Loc: Oregon
Reg: 03-31-05
10-12-21 08:26 PM - Post#2829062    

I had a pre-cat O2 sensor go out and while I was under there I noticed that I had a fair bit of oil on the torsion bar cross member behind the transfer case. I started watching where I parked and noticed a couple of drips here and there, but nothing drastic. Finally got around to checking the fluid last night and it took almost 2 quarts before it was full. Overnight there was a couple of small drips again, that seem to be coming from the fill plugs. Has anyone else had issues with this? Can these dump fluid while running, kind of opposite of what the water pumps used to do?

I'm not hearing any strange noises, but I've had a bad muffler for 3 years or so and just got a magnaflow put on, so it's tough to hear relatively quiet noises. I'm not real excited about the idea of tearing it down, but I suppose if I have to it doesn't look too complicated from the your tube videos.

This is my 2004 2500HD, it's been a while since I was here so I'm not sure if it shows up in my signature . . .

Jordan

2004 Chev Silverado 2500HD 6.0L 4x4
2000 Oldsmobile Bravada
2011 GMC Acadia - NIGHTMARE


 
wreckmech 
Member
Posts: 255

Loc: Parsippany, NJ
Reg: 10-08-02
10-13-21 06:34 AM - Post#2829073    
    In response to JLDT

Check for the dreaded "transfer case pump rub"...You can Google it, and you'll get a myriad of hits. The transfer case pump chucks back & forth while shifting, and rubs a hole in the top of the transfer case housing. Since it's at the top, it won't leak while sitting static. It splashes out while being driven, and the drops you see in the driveway are residual dripping off. I have fixed this numerous times on customers trucks.

GM's "fix" sucks...I usually recommend Merchant Automotive's upgrade kit....Good luck



 
JLDT 
Member
Posts: 274
JLDT
Loc: Oregon
Reg: 03-31-05
10-13-21 06:07 PM - Post#2829119    
    In response to wreckmech

I had read about that, I thought the hole was at the bottom though and wasn't seeing it. I guess I'll have to see if I can get a scope up there and look to see if it has come all the way through. Thanks for the info.

I also have seen the case saver plates as an option, which is a little cheaper than the MA set up. Do you have any experience with those?

Jordan

2004 Chev Silverado 2500HD 6.0L 4x4
2000 Oldsmobile Bravada
2011 GMC Acadia - NIGHTMARE


Edited by JLDT on 10-13-21 07:00 PM. Reason for edit: No reason given.

 
wreckmech 
Member
Posts: 255

Loc: Parsippany, NJ
Reg: 10-08-02
10-15-21 07:33 PM - Post#2829237    
    In response to JLDT

I did 2 of my trucks with the MA kit. You can get them for under $100. I honestly never looked any further after I got my first kit.

I have found a couple of the stainless clips that GM put in as the "fix", cracked. The hardest part of the job is the snap ring that holds the bearing for the chain. It can be done without the special snap ring pliers, but it's a real bear.

I've never had any more issues after installing the kit. I know RockAuto sells the case half for around $250 if the case has worn through. I've heard of guys using JB Weld to fix holes, but I'm not sure I would trust that repair.



 
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