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Transfer case issue

21K views 9 replies 4 participants last post by  bootstrap  
#1 ·
Hi new to the forum and looking for a little help. I usually hate long posts but I'm trying to give as much info as possible......

So I have a 2005 GMC sierra 1500 with 155,00 km and I've had it since new. Only issue I had was/is it didn't go into 4L. I hit the button and it bangs and tries and never does but this is not an issue since I never use it. I had it at the dealer for another issue and they looked at it and said the transfer case has issues inside and needed to come apart. That was 3 years ago and I never did get it fixed as it works great for all other functions and I never use 4L. Other than that its perfect and never had an issue. I've changed the oil every 50,000 km in the transfer case

3 days ago when driving I noticed it was in 4 auto which i thought was strange cause I always leave it in 2h so I hit the button and it switched back. I was leaving my driveway later that day and backed out then put it in forward and terrible
grinding noise and no forward drive, then no reverse and bad noises in neutral. I put it in park, it ground to a stop and then I put it in forward and everything was normal. Then drove 5 km and tried to park and put it in reverse and then grinding noise was back and lost all gears. I put it in park and nose stopped after the trans ground (parking pawl ?) to a halt. I put it in forward and it drove again so I parked without going into reverse. Then came back and my truck had rolled ahead 4 ft. But I drove home with no issues but just put it in drive and that was it.

Next day I tried to back out of my driveway and had no gears and just bad grinding noises. I put it in 4 auto and it then drove ok in all gears. Tested it in all gears and in 2h, 4h, 4 auto and now everything is normal again. I drive down the hiway in 2h and was going 100 km/h then slowed down to 60 km/h for traffic and then hit the gas again and had no gears and grinding noise. Coasted off the road and no reverse and grinding noises till I put it in park. Then put it in 4 auto and in worked fine to drive again. After a stop at a marina it put it in 2 h and again now everything is normal

So I drained the transfer case and expected to see chunks come out but the oil didn't look bad and found nothing with a magnet in the drain hole. So is it for sure transfer case ? Does it have to come out and apart ? Could it be an electrical issue shifting something out of place ? Worth to rebuild or buy a new complete ?

Thanks
 
#2 ·
First thing to check would be the shift linkage for the transfer case, to see if it is binding or if there is any play or other damage.
If it sticks for any reason, the servo motor will not be able to engage the gear ranges properly. i would start there.

CarMech97
 
#3 ·
Sounds like its popping out of gear. When you put it in park its able to re-engage but eventually it pops out again. Have you been using autotrak II fluid? Definitely time for a t-case overhaul. And I'd do that soon as it may leave you stranded.
 
#4 ·
CarMech97 said:
First thing to check would be the shift linkage for the transfer case, to see if it is binding or if there is any play or other damage.
If it sticks for any reason, the servo motor will not be able to engage the gear ranges properly. i would start there.

CarMech97
Thanks for the reply,

So to do this do you remove the servo motor and manually try to shift with a screw driver or something ?
 
#5 ·
bootstrap said:
Sounds like its popping out of gear. When you put it in park its able to re-engage but eventually it pops out again. Have you been using autotrak II fluid? Definitely time for a t-case overhaul. And I'd do that soon as it may leave you stranded.
You bet GM autotrak II is all that has ever been used.

Its out of commission till I get it figured but if it is the transfer case
1.Pull trans case and get it rebuilt and then reinstall
2. Put in a new transfer case ( I need to call around for prices)
3. Put fluid in it and take it to a shop
 
#6 ·
Big Ben said:
Thanks for the reply,

So to do this do you remove the servo motor and manually try to shift with a screw driver or something ?
The idea is to observe the mechanism for proper operation, as an assistant cycles the transfer case through the different ranges.
One thing that I learned about this trade is that a good visual inspection will reveal the problem 85% of the time (so they say).

Unless it's electrical - well then, you got troubles :lol:

Good luck with it! Let us know what you find out.

CarMech97
 
#7 ·
Well thanks again for the replies so here is my follow up......

With 1 kid 2 years old a one 3 weeks I don't have much time to mess around and if it had been a few years ago I may have tackled this more myself but not the case right now.

After talking to the dealer for prices and a independent shop, given the issues I was having with no 4lo and now jumping out of gear it only made sense for a new complete GM full GM warranty transfer case from the independent shop. I was thinking about R&Ring it myself but they quoted 3 hrs plus parts I can barely get my truck on stands and oil drained in 3 hrs lol.

So called on Wednesday, parts arrived thursday and it was done today. I wanted the old one back to disassemble and inspect when I got some time but they said the "core" had to go back which is strange if its new not exchange.

Anyways glad to have my truck back and thanks again for the great site with good info to help me make my decision
 
#8 ·
Yea let us know if you have more issues.
Its always going to take you much longer to do the same job then they will. The incentive to do it yourself is obvious: saving lots of money. It wouldn't be a bad idea to climb under there and look for loose bolts or linkage. Sometimes those bone heads are in a rush.
The core charge is normal. Im not sure but they might not be making those transfer cases anymore, so a core is necessary for them to rebuild it and sell as new "remanufactured."