Canamatt

I just wanted to pass along a problem I have had with transfer cases on my 2003 - 2006 Suburbans. I am responsible for a small fleet of 15 vehicles. I have 6, 2500 series Suburbans as well. In the past 5 years I have changed out 5 transfer cases, 4 non - warranty and 1 warranty. Between 80,000 kms (50,000 miles) and 120,000 kms (75,000 miles) The last 3 I have had disassembled to determine failure. In every case a small tab on the throw out bearing has broken off causing the caged roller bearing to spin (metal on metal) with the shift fork, overheating the bearing to the point it would fly apart and send scrapnel around the transfer case.
After discussing with the owner of the shop (a GM guy for years) we decided that operating the trucks in Auto 4WD was causing this (too) small a tab to slam into the shift fork every time the truck broke traction, eventually breaking it off.
If GM designed this tab bigger to allow less free play of the bearing and more meat making it less likely to break I believe I could have saved the $16,000.00 ($4000.00 each time) I have spent on transfer case replacement.
Personally, I own a 1999 Tahoe. After this lesson I will avoid using Auto 4WD in favor of either 4WD Hi or 2WD.
I will try to attach some photos. Any Comments?


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Enema Combatant

I think my wife has been operating the truck in A4WD. I'm out of town, but she's told me the dreaded "It's showing RED LIGHT, and I can't shift it into any other modes" speech.

Is this how it usually manifests itself?