Routine maintenance revealed a leak in the transfer case. This lead to discover a small hole in the case. This is caused by a part defect that breaks over time. Usually around 85,000 to 105,000 miles. The part is an "anti-rattle clip" that prevents the inner pump from of course rattling. When this part breaks, the pump then rubs a hole from the inside out. If this is not caught in time, the lubricating oil would run dry and this would lead to a drivetrain malfunction. I will be ordering a replacement transfer case. Yes old part will be available. Note: As of yet, the replacement part for this has no modifications to prevent this from happening again.

- Fremont, UT, USA

: the contact stated the transfer case punctured internally and the oil drained out when driving around 25mph. The contact heard a knocking noise and took the vehicle to an independent repair shop for inspection. The transfer case was faulty and the repair part was ordered.

- Grandville, MI, USA

I own a 2002 chev K2500hd. I have had several problems, but was unaware of this site to report these problems until now. First, the dryer switch on the ac went bad @ 34K. Second, @ 65K I had to replace the front left wheel hub assembly as talked about in one of the other complaints I read. Third, @ 95K my transfer case developed a leak and I lost all the fluid. A Chevrolet mechanic showed me a transfer case that had gone bad due to the same problem and had been used in 4WD w/out fluid in it. Another Chevrolet mechanic told me he had seen several of these and that "jb weld is your friend". so I patched the hole, and 10K later it developed a second leak in a similar location and also about this same time an electrical part (about $550) went out for my 4WD. Now at 130K it has developed a third leak! also starting @ approximately 50K, my rear differential has locked up on me several times and I have had to replace 4 cables on my tailgate. After being a Chevy man all my life I think I will look at Toyota.

- Markham, TX, USA

Pump retaining pin on the transfer case failed, permitting the pump to wear a hole in the transfer case with sudden release of the engine oil. Chevrolet is not claiming knowledge.

- Mountain View, WY, USA

The vehicle was unable to engage 4 - wheel drive. The dealer stated that the front axle actuator failed.

- Oregon City, OR, USA

While driving driver's side front tire blew out, causing the wheel to lock. The 4-wheel drive will no longer properly operate.

- Deep Water, WV, USA

Consumer stated while traveling with 4-wheel drive on and without any indication two wheel drive would engage, resulting into poor tracking.

- Wilmington, DE, USA