I have a 2003 6.6. , six months ago I noticed a clunk sound when I would accelerate from a dead stop. Dealer thought it was maybe u joints. I brought it back again because a friend checked it, said my u joints were fine and thought it was coming from the transfer case. Brought it to the dealer and they found a hole in the transfer case. A clip in there that holds the pump broke and the pump has made a hole in the housing from bouncing around in there. They are going to repair it with some new clip design, but also have to put in a new chain because my chain has slack in there from driving with little oil in there. Has any one had this problem? Is the wind up clunk from this to. They are putting it back together tomorrow. Hopefully will be ok.

do a search for "pump rub"

You'll find tons of information on it.

Also, you can check my photo album for photos of where the hole is on mine.

http://duramax.onlinedesk.net/photos/index.php?album=2003%20Duramax%2Fpumprub%2F

Yea look at the thread I made about it......just another one of those Dmax FLAWS you have to deal with.

The clunk you felt at acceration from a dead stop is the slip yoke in the transfer case is dry, a dab of grease will fix that, the Bozo's at the Dealer should have known that.
The pump rub, is another matter, ans yes it is a big problem, I have found it to be a bigger problem than injectors around here from just asking the farmers about thier injectors, and then showing them the hole.

Glad to hear they are getting it fixed for you.

GRRR!

I took my truck to the dealer two weeks ago to have a leak fixed from the transfer case. Their solution was to replace the gasket between the t-case and allison. I knew that wasnt the fix, but decided to go through the process.

Sure enough, I get home an hour later and crawl under the truck and its still all wet and leaking.

I took it back yesterday morning with a photo of the hole and said, pump rub...go fix...in fact it was driping oil on their floor.

I called them around 3 pm yesterday and they said, we dont know how to fix it. The system only tells us how to do preventative maintenance if we have to take the t-case out for other reasons.

I said, you fix it by replacing the back half of the case. He said, well, we have to wait on the regional service manager to confirm.

I called a few minutes ago asking for an update. They said the GM adjuster will come out sometime tomorrow and look at it and decide what to do.

Seems to me that the extended warranty place is trying to get out of fixing it. The extended warranty expires on Oct 7th. So far they have paid for about 1100 in repairs on the truck.

My guess is they are gonna look the truck over for performance upgrades and try to deny the claim on that.

So my question, is there an official TSB or GM document that says anything about pump rub and how a dealer is supposed to fix it?

The truck is in stock form (including tires).

Can someone with access let me know if this document relates?

Document ID#1962218

http://service.gm.com

Subject:Improved Oil Fluid Wear Pump Clip - keywords 136 149 246 246EAU 261 263 263EAU housing leak case transfer transfercase #PIP4118 - (04/17/2007)


Models:1998-2007 Light Duty Trucks and Utilities
Equipped with New Venture Gear Transfer Cases RPO NP1, NP2, NP3, NP4, NP8



The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.
<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1962218&evc=numSrch#ss1-1962218">Condition/Concern:

Oil pump wear clip P/N 12470559 is broken or out of position. This may cause the pump to wear a pin hole in the transfer case rear half. If the wear is severe the transfer case may be damaged due to lack of lubrication. The clip may fatigue and break. The clip may become loose and shift out of position.
<A href="http://service.gm.com/servlets/BlobShtml?ShtmlFile=1962218&evc=numSrch#ss2-1962218">Recommendation/Instructions:

A new clip design has been released. P/N 89059653 is available for both production and service. This new part totally cancels and supersedes the former P/N 12470559. Only the new clip will be available.
This new oil pump wear clip should be used whenever a transfer case is opened for any type of internal service. See photo. GMSPO currently has inventory of the new part.

http://service.gm.com/engif/000/001/962/1962199.gif
http://service.gm.com/tif.gif (http://service.gm.com/servlets/RetrieveTif?pic=1962199)

Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.

Thank you.

So I guess they are stumped because this document doesnt tell them what to do when there is a hole worn and they dont know if they have to replace the whole t-case (I was told that is $1800) or just the back half.

I had to take the truck back to this dealer for servicing because they used a 3rd party company for the extended warranty.

I would say your right, but sometimes with extended warranty companies, the company will send out an inspector to examine the parts, then based on his decision the company will decide how to repair, or in some cases if they will cover it. The dealer should be working pretty hard to get this covered, because with the extended warranty companies, they charge them full rate out of the labor guide, and usually then some, so they are making good money on this job as well.

Riley

If the extended warranty company knows its a common issues, wouldnt they also put pressure on GM to cover it or split the difference? I would imagine they have more weight against a selling dealer then a customer would.

Or perhaps this small town dealer just doesnt know what to do. Not sure why that would require an adjuster to come out.

I was lucky. I got a case half for 180, and the pump upgrade from eric for what...250? hour and a half labor...i was done...just another one of those flaws you have to deal with

If I was out of my extended warranty, I would probably do that.

However, my extended warranty explicitly states that it covers transfercase leaks from internal parts wear.

GM has acknowledged this as an issue, they have a TSB that instructs the replacement of the wear clip if one should be in the T-case servicing it for other issues.

I hope its just the local dealer not knowing if they need to replace the rear half vs the whole unit or what parts they should replace.

Oddly enough, I can bet that if I was out of warranty and asked the dealer to fix it, they'd sell me a whole new t-case and say that was the solution.

I would say you are right about your dealer attempting to replace the entire case vs. what needs fixed. I worked for a small town dealer, and any time I removed a 4L60-E for the usual sunshell, we almost always had an inspector come out if it was an extended warranty. Our dealer usually sold AUL Contracts, and Vehicle One

Riley

So here is the scoup so far.

The dealer has the t-case out and apart on the bench. They say it has shavings in there and needs a new pump, clips, seals and rear-half and maybe the chain too. The price tag is over $1k.

The warranty company is sending out an adjuster to determine wether they will fix it or not and if so, what they will do. To me there is no debate.

Their paperwork states Transfercase Assembly: Transfer Case (damage as a result of failure of internal lubricated part), gears, shafts, forks, shims, bushings, spacers, chain, carrier, internal electric controls, bearings, thrust washers, spacers, synchronizers, internal springs and position balls, locking pawls, fluid when repairing transfer case and fluid when reparing transmission.

So what part of transfer case rub DOESNT fall under that. :)

The dealer seems to be on my side. He pointed out the TSB that references the failed clip and replacement redesign. Additionally, he worked through the issue where they claimed my warranty expired in February when in fact it expires October 7th, this Saturday.

Tell them to give you 800 bucks and then go buy the pump housing from M/A and then use some JB Weld and repair the case and install the pump housing and pocket the 550 bucks for beer afterwards.

I would do the job for 550 bucks, and I will do the work and supply the parts.

I am NOT solicitating work, I am just trying to make a point.

I'd do the work myself too, however since they had to come and look at the parts and want a list from the dealer to pay the costs, I am letting the dealer do it.

I did make the extended warranty pay me for both front hub assemblies and labor to do it. I then pocketed the difference.

Anyways, the parts are on the way and will be there in the morning.

Total bill to the extended warranty company will be around $1100.

I know its a new tail housing, bearings, some bushings, etc.

I just found out yesterday that my leaking seal is actually a hole in the transfer case...probably pump rub. I've got a 2003 with 90K miles, so it's beyond the warranty...repair shop says I need a new transfer case (guts and all) which sells for $1900 (+labor).

what other solutions are there? is this the only way to go? will I run into the same problem is the problem fixed in the new transfer cases?

thanks, John

If you didn't run it low on oil, I would follow Tolli's advice on post #16.

If you did run it out of oil and the TC is junk, at least have the repair shop install one of the pump upgrades.

Merchant Auto and Kennedy Diesel have upgrades, I believe others do as well.

Nice name BTW.

SS396, nice Velle...happen to be a member or Chevelles.com?

Thanks for the advice, this is a mess...can't believe how many trucks have experienced this. And it's not a cheap fix either.

John

John, I am not a member, but thinking about it.

What Chevy classic do you have? A Velle owner too?

So I take it your TC is junk? The fix is easy to do, perhaps try to find a TC from the junk yard. If you haven't already I would contact Eric at Merchant Auto to find out your options on a TC.

Do I need to replace the pump? If so, is there a good aftermarket place to get one? What about the clip? I just want the noise to be gone. I still haven't found a hole there yet. No wetness or anything. But it was out of fluid. I put my pocket magnet in the drain hole and it came out relativly clean. I still have the noise when I drive,and it doesn't seem to change when in 4WD

Merchant automotive, a vendor on here.

Or look up thier website