Got a manual trasfer case?? (HELP!)

04wolverine · June 22, 2006

DOES YOUR MANUAL TRASFER CASE MAKE NOISE??????I have a 2004 chev 1500 4x4 with 4 :10 gears and a manual trasfer case. I have had it in to the dealer twice now with the complaint of transfer case noise. It sounds like a bearing wearing, sometimes almost like the sound a throwout bearing makes on a standard transmission when it is about to go out. It gets worse when hitting bumps or after a long drive on the highway. It is not overly loud but annoying as you can hear it all the time wether coasting in neutral 4 low 4 high or 2 wheel drive. The dealer keeps telling me this is normal noise for the manual case but I dont believe them. My warranty expires in 3000 miles . I serviced the t case and checked for leaks with none apparent.

Any suggestions???

Thanks guys.

sc4808 · June 23, 2006

Yes, I'm glad that you asked, mine did the same thing. I have a 2003 Sierra. Mine made a noise from the time it was new, it lasted until the truck had 90K miles and then the rear output bearing came apart while I was traveling at 70 mph on the interstate. It cost me $1400 to put a Jasper remanufactured TC (transfer case) in it.

Get under the truck and see if you have any up and down motion where the rear driveshaft comes out of the TC, if so, you also have a bad bearing.

One other thing, mine has a small noise to that comes from the TC shift lever, if you look at it from the bottom you will see a rod that goes from the shifter to the TC, it has small ball joints on each end, if you grab the rod and shake it you will hear the rattle noise (if it is like mine). The solution for this is to take the linkage off and put some heavy grease in the ends, that noise will stop then. To see if this is what is making the noise on yours, put a little preasure on the TC shifter when ot is the noisest (while driving) and see if it goes away.

By the way mine is quiet now.

Funny thing is, the 261 is a heavier duty case than the autotrac case but has more problems, go figure.