Chevy Truck Tansfer Case Factory Defect

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Chevy Truck Tansfer Case Factory Defect

Postby Rich461 » Mon Apr 30, 2012 1:07 pm

This goes out to anyone who owns a half ton (1500) 2000 model year and up to present 4x4 pickup.
Your transfer case has a built in defect from the factory and they aren't going to fix it!!
I was recently coming back from a fishing trip when all the oil in the transfer case came out of a little hole.
It was repaired by a local transmission specialist I have known for 20 years. He showed me what happened
and then he told me why it happened.

There is a round ring plate at the back end of the output shaft that has 3 tangs on it. One of those tangs
fits in a slot. When you put your truck into gear this plate rotates about an inch inside that slot. When you
take it out of gear it moves back. This happens every time you go into Drive or Reverse, in 4WD or 2WD.
After about 60,000 miles this plate has worn a groove into a steel sleeve it rides on. Any time after 60k the
plate can slam into the the side of the case and put a round pinhole into the case, which the oil pours out of.
You will know this is beginning to happen when you hear a metallic sound, like a bad u-joint clanging, when ever
you put it into gear. When it gets really bad, you will hear the same sound when it shifts from 1st to 2nd.
When you hear this sound, run, don't walk to your nearest trusted transmission specialist and have him take
the TC apart and replace the two ring plates with an after market one that does not do this. If you do it before
it breaks the thru the casing it will only cost about $500 to $800 to repair. If you wait, it will cost over $1500 to
fix it. If you don't believe me, just go to google and type in 2003 Chevy transfer pinhole leak, and read the
hundreds of cases that appear on those forums. Chevy has known about this for years but will not fix the design flaw.
They say that since no one has been killed because of this problem, they do not have to recall and repair the flaw.
Just thought you guys might like to know.
1997 Ranger 461VS

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Re: Chevy Truck Tansfer Case Factory Defect

Postby Marc » Wed May 16, 2012 8:41 pm

Does this also apply to a 2006 Yukon Denali?

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