2003 Chevrolet Silverado LS from North America - Comments

At approximately 50K miles I noticed an oil leak from the transfer case. I took it to the dealer in my area who diagnosed a faulty top seal on the transfer case, and charged me $500 for the repair as the vehicle was no longer in warranty. Two weeks and less than 1000 miles later, I noticed the same area was leaking. I took it back to the dealer and the technician told me "you have pinholes in the side of your case, it's like a flaw in the casting". They told me they would clean it off and apply a layer of JB Weld to it to seal it up. Well 3000 miles later guess what, it still leaks. GM customer care and the dealer told me I need a new case and they would gladly pay "half of the repair" ($875 would be my half). I feel it's a mfr defect, they know it is, they should pay for it all.

It has been a great truck, my third new Chevy

Lots of power

OK mileage for a 4WD

Very roomy interior

Rides better than my wife's Sebring Lxi.

Re: GM Transfer Case Leak.

I've recently replace the transfer case with only 69000km on my 2003 GMC2500HD for the same (fluid missing) grinding metal particals reason. I also found that GM issued TSB that I located at http://www.dieselplace.com/forum/showthread.php?t=166491&page=7 (then see item #67)

The GM Bulletin clearly defines the problem and has recommended the fix however GM have never issued a recall.

I have completed a substantial internet/google search on the topic of GM Transfer Case Leaks and the pinhole problem is the recurring cause. Apparently the cause is that the TC oil pump clip comes loose and eventually grinds a hole in the case, draining the fluid etc.

GM's Customer Care person was returning my calls and being very nice, up to the point that I told them I could send them a copy of there own TSB that proves GM recognized the problem and its cause together with a definitive fix.

I'm sure that GM CCC could obtain from its parts department, the number of replacement units/rebuilds and to this it should add the number of dealer and other repairs to rebuild and or weld the case.

Essentially, GM should have issued a recall some time ago, however, the Transfer Case recall concept would be very expensive, and not a carrier builder for the Executive responsible.

I remember hearing that Ford had such quality control problems with certain electronic parts in the early 60's and it refused to deal with its customers in a forthright manner. It took a few generations to rebuild its customer base as GM was the beneficiary at that time.

GM must realize that Toyota, Ford, Chrysler and a number of other manufacturers make perfectly wonder vehicles, and must also realize that it is much easier to retain a customer than to solicit new ones, especially after mistreating the last client-base.

Yes this problem is expensive, but it will not go away unless GM take definitive action that solves the cause. However, the suggested fix (as outlined in the above mentioned TSB) that somehow a mechanic will find and fix the problem before the TC self-destructs is wishful thinking that begs the question:

Who is paying for the GM mechanic to find the problem that GM should have recalled but has not?Answer: Owners.

The logic escapes me, and GM needs to understand the ramifications as we all have more than one vehicle in the driveway and there are many excellent mfgrs vying for our business.

Perhaps Car Survey could aggregate the owners to this problem as we should be making a united presentation to GM.

R. Hay.

I just joined the hole in the transfer case club with my 03 Silverado. I had 73K miles and it will be costing me $1200 today. I noticed through other sites there was a tech notification sent out in 07 which discusses the 1998-2007 light duty trucks and utilities. GM knows this has been a problem and they have come out with a fix but not a recall. Looking through other sites and blogs, there are a lot of repairs being made at our expense which GM should be taking care of.

Apparently I'm now in this club too! My 2003 Suburban has developed the leak "according to my mechanic"...

Has anyone made any progress with GM on this issue? This is going to really stink!

I'd also be curious as to what others have done to resolve the issue!

-matt-

I recently had the same problem with my 2004 2500HD Duramax with 160 klm's, (about 90,000 miles. Dealer told me it was a seal but I took it for a second opinion to a local transmission shop. The owner crawled under the truck and told me I had a common problem of a pinhole. $1500.00 Can later I'm good to go. Looking at Fords now.

I have a 2002 Chevy Duramax 4x4 with 171,000 miles. I took it into the dealer today for an oil change and was informed that I also have a hole in the transfer case. I was told that it was caused by the clip from the oil pump and it would cost $800.00 to $1800.00 to fix the problem. They also told me that even with the fix it can happen again.