Okay, tonite I've verified I have now officially joined the "pump rub club"...thanks, GM. :(

So who has the highest mileage before the "hole"? I hit 196,000 km approx (or 118,000 miles) tonite.

In the meantime, time to find some JB Weld.

I joined today as well. I have a 2001 3500 LT 4X4 D/A Crew with a long bed. Found my problem a little too late with 178,000 miles on the clock. I checked with Chevy parts and the cases can be ordered in seperate pieces. Not too expensive. But then I have a quad with JB weld on the transmission that has held for years. You may be on to something....

Mine was there when I pulled the truck into the driveway from the dealer and that was at 139,000. Dont know how long it was leaking before that. The dealer did replace the t-case.
I learned about pump rub (and the Diesel Place) after buying the truck, then searching for an answer to why there was fluid leaking out of it and onto the driveway.

almost 102,000 miles no issues, knock on wood.

119k no hole yet knock on wood. just changed it over to 5w-30 amsoil too.

112000 no hole as of yet! Holding my breath!!

new guy here, but what is pump rub?

110,000 nothing yet

no pump rub for me!

Replaced the Xfer case at a 189k miles on an '05 3500SRW and it had no rub hole (or even excessive marking at the internal contact points). It was however scrambled due to no oil from a tailshaft bushing failure, attributable to a bad front U-joint (and a driver who didn't hear anything).
The only reason for further inspection was the ABS lamp illuminated.

Never, in my fleet, have I seen the pump rub hole on any of the trucks (although I know to look for it).

I found mine at 168,000 miles, patched the hole, drove for another 10,000 miles and then installed the M/A pump housing. all is well now!

new guy here, but what is pump rub?

A tiny hole gets worn in the transfer case from the inside out due to an internal clip breaking and the pump getting misaligned and it then rubs against the case causing the "pump rub".

Someone correct me if this is wrong.

Do a search. There is a lot about the topic and even how to fix it.

60k still ok for now.

108,000 and still going strong!

Just found ours last week. 96,000 miles. While it's down, we're installing the M/A pump upgrade kit, a new outer case (price wasn't too bad for peace of mind), and since some of the oil leaked out and was low, the teflon coating on the shift fork got hot and flaked off, so new fork.

I have a 111,000 on mine and just had the output shaft seal go out. Good thing I caught it when I did. I hope the "pump rub" issue does not come to me soon.

146,000 miles, so far so good

300,000 Miles when I had to repair it,so far no leak,did the in the truck repair :D

250,000 before mine started the hole. JB weild and the plate for mine

210,000 miles and still okay. I check everyday now. I love my DMAX!!!!!!!!

Subscribing, I was thinking about starting this thread yesterday... thanks.

I had 82,000 and mine was TU. I've got Eric's prototype pump plate.

Did GM do a "fix" for this?
I noticed that many of the posts were for 2002 through 2005...

Gm came out with a new pump clip that isnt worth crap. Anything from a S10 to a 3500 and SUV from 98 to 07 will have pump rub. I have seen them from anywhere with 15,000 miles on them since i fix many GM warranty units for dealers and some last 150,000 plus.

Dan

Had mine at 140,000, trashed the t-fer case but love the rest of truck. 2001 Duramax.

Did GM do a "fix" for this?
I noticed that many of the posts were for 2002 through 2005...

Yeah, they came out with a new tranfer case.

Will pump rub still exist on the LMM's? Has anyone heard of this problem on the 08's?

I had Eric Merchant install his upgrade at about 62k, before anything ever happened. Life without pump rub is good. :cool:

102,000, hole appeared , Merchant upgrade now life is good

90k and no issues, knock on wood.

BTW, did you say "rub" and "poll" in the same thread title?:rolleyes:

:D

182k and not an issue.

I had first hole at 175k in 3 o'clock position. Second hole at 200k at 12 o'clock and third hole at 215k at 6 o'clock. The 6 o'clock would have emptied the case of oil quick if I hadn't caught it.

All signs are pointing to the fact that I should fix this proper before the transfer case cuts itself in half !! I'll get right on it someday.

What is the best / cheapest permanent cure of all the kits out there and where is the best place to get the new case half ?

Any guesses where the fourth leak will appear?

I had first hole at 175k in 3 o'clock position. Second hole at 200k at 12 o'clock and third hole at 215k at 6 o'clock. The 6 o'clock would have emptied the case of oil quick if I hadn't caught it.

All signs are pointing to the fact that I should fix this proper before the transfer case cuts itself in half !! I'll get right on it someday.

What is the best / cheapest permanent cure of all the kits out there and where is the best place to get the new case half ?

Any guesses where the fourth leak will appear?

got mine here http://www.kennedydiesel.com/categoryresults3.cfm?Category=11&SubCategory=109&SubCategory2=135 and used JB weild to repair the hole

49000 and no hole, but I put the plate in anyways. Good thing, because the clip was still there, but the clip put a small indention into the case. It was only a matter of time before it caused a hole.

113,500 miles and no hole yet!:D

I put the plate in at 186000kms. I

I put the plate in at 186000kms. I thought this pump rub thing was B.S. it is not. The clip was almost wore through and the case was damaged as well. happy I fixed mine now. DO IT.

187000 and no hole. God blessed me with a good truck!!

Two parts to this question:
1. Where can I get a service manaul or CD for my D-Max?
2. If I purchase the plate - is something I can do myself?
While not a mechanic by profession - I can do most major repair work on gas and diesel. I just do not like like it when all of a sudden you need a very special tool ...

John

197K and no hole. Minimal wear on the inside of case. I'd guess it would have made 250K but the front half went out of my case so it's getting a rebuild with a plate.

Two parts to this question:
1. Where can I get a service manaul or CD for my D-Max?
2. If I purchase the plate - is something I can do myself?
While not a mechanic by profession - I can do most major repair work on gas and diesel. I just do not like like it when all of a sudden you need a very special tool ...

John

Takes about 4-6 hours depending on conditions and expirence and just how much plain ol Mechanical abilities you have.

Easy fix, This is how I did it in my driveway on Jack stands.
http://www.dieselplace.com/forum/showthread.php?t=140732

Here is a link to Merchant Automotive's Excellent Picture and directions to cracking the case and installing the pump housing.

http://www.merchant-automotive.com/tech/tcp.pdf

Took me and my buddy 3hours to do. We did it on jack stands.My buddy is a GM master mechanic he is good. We are doing my father in laws lly sat morning.

126K and no hole yet.

i am up to 100k and now hole. i got the kennedy upgrade going in this weekend. i hope i dodged a bullet with this upgrade because my last truck had the hole at about 110k

Mine went 196,??? miles before it happen and that was just last week. I didn't notice it till I got home after 800 miles. It was bone dry when I went to check it.

My case was cooked I found a local one with 65,000 miles add the Merchant Automotive pump upgrade. It took me about 3hr and $1450 but its fixed now.

repaired mine befor it wore thru looking at the wear it was over half way at 102000

is there a good fix cheaper than kennedys 250.00 no cashola and approching 100,000

is there a good fix cheaper than kennedys 250.00 no cashola and approching 100,000

Kennedy's fix is only $50.00 plus shipping, plus labor and incidentals. Merchant's fix is $250 plus.....

Has any body done the kennedy fix and if so does it just protect the case, where merchant fix prevents the pump from wearing thus preventing the rub? Or am I confused? HELP!!!

Has any body done the kennedy fix and if so does it just protect the case, where merchant fix prevents the pump from wearing thus preventing the rub? Or am I confused? HELP!!!
did mine friday night and yes it works! it was hard to see just how it would work until I got it in then you can see it prevents the pump from getting near the case. thinking of buying 1 more to help my brother out with his z71, he helped keep the Jim in my cup while I was working on my transfer case!

i did the kennedy fix this weekend as well. I personally believe that it is a better idea than the merchant fix. the kennedy plate is steel and the merchant is aluminum. they both give about the same surface area on the transfer case housing. at first i thought the merchant fix was 1 piece but it turns out that it is not so i would just think these parts could potentially break off at some point and time. I know that they probably never will but the oppurnitity is still there. when i installed my kennnedy plate i stuck it to the rear case half and put just a small dab of silicon to hold it in place. i am happy with it and like said above the kennedy is 50+shipping then you will need the transfercase gasket that goes to the adapter..

i did the kennedy fix this weekend as well. I personally believe that it is a better idea than the merchant fix. the kennedy plate is steel and the merchant is aluminum. they both give about the same surface area on the transfer case housing. at first i thought the merchant fix was 1 piece but it turns out that it is not so i would just think these parts could potentially break off at some point and time. I know that they probably never will but the oppurnitity is still there. when i installed my kennnedy plate i stuck it to the rear case half and put just a small dab of silicon to hold it in place. i am happy with it and like said above the kennedy is 50+shipping then you will need the transfercase gasket that goes to the adapter..


The M/A is a ONE PIECE unit and ALOT Better for surface area, I do not know what you looked at, but the M/A piece is a better piece. The Riverside Gear piece sold by Kennedy is a cheaper part, it will do the job, but not the same caliber as the M/A item.

I've ordered the Merchant piece and should receive it in the next week or so. Looks too nice to be covered up.

160000 and got a hole. These trucks are kinda shity my truck breaks every other day so Im back to driving my 95 1500 5 speed 4x4 with 208000 miles.

120,000k for first hole dumped fluid paid the dealer to repair..Now 157,000 miles and another hole appears, GM not willing to help and will be on the hook again. Would appreciate any help with this and sounds like there area couple tried solutions to the problem.

148mi no hole yetm but I check every other weekend!

Does this effect the LB7? and where is it. Love to see some pic's so I can see if I need to do this as well. I don't know what pump or where to look.

114,000+ and no problem yet. Knock on wood! I am under my truck every weekend looking for potential issues and this is one of them. Always vigilant.
HeRattle.... rear half of the transfer case. Small hole develops. Obvious sign is fluid splash on cross member, drive shaft and points beyond.

114,000+ and no problem yet. Knock on wood! I am under my truck every weekend looking for potential issues and this is one of them. Always vigilant.
HeRattle.... rear half of the transfer case. Small hole develops. Obvious sign is fluid splash on cross member, drive shaft and points beyond.


X2, the hole develops above the normal liquid level, thus you will only lose fluid when driving, and no driveway puddle will tip you off. There are pics if you search.

Does this effect the LB7? and where is it. Love to see some pic's so I can see if I need to do this as well. I don't know what pump or where to look.

Yup, it'll affect you. Search "pump rub" for pics. Also, check Eric Merchant's website and you should find pics of the hole and Eric's solution to the fix. Alternatively, Kennedy's also has a fix to the "rub" with a plate.

Basically, the pump material is harder than the magnesium t-case and once the pump rubs through the OEM clips that separate the pump and the case, it's only a matter of time before the pump rubs an 1/8" hole in the rear half of your t-case and thus you will drain your 2 quarts of fluid out.

Here's a pic of my t-case with the hole...you should see something similar looking at the rear half of your case if you are unfortunate enough to join the club. Notice all the oil around the case.

Got my pump rub hole at 124,000 miles.

took me 99,000! How exciting, good thing Eric Merchant lives 10 miles from me.

I replaced clip and half of the transfer case at 122,000 miles. It is wonderful that GM can't recall a clip that is 7.00 that holds the pump in place so it doesn't rub the inner wall of the transfer case. No wonder they are trying to file bankruptcy

Newbie question:
which years are affected by the "Pump Rub"?

Thanks,

repaired pump rub issue at 162,094 miles

stock- i believe 2001-2007. supposedly fixed now? and im in the club now 116k

i have a 2001 8.1 with 305000km no pump rub and my dad has a 03 duramax with about 270000 km on his and it still looks good must be luck i guess

charlie, thanks,

101,000 miles, no hole yet.

101,000 miles, no hole yet.


same here 105K on the clock and no hole:D

230,000 miles and oil all over under truck. It's gotta be pump rub but still have not found
exact location of hole. Been a good Suburban until now, original brake pads, alt, water pump. The Dmax is 2WD and that's great....... until it snows.....it simply wont go anywhere!

The pump rub is at the transfer case and the two wheel drives ( unless I am missing something) dosent have a transfer case.

110000mi and I had a small hole

got mine at 105,000mi

53,000 miles I WILL NEVER BUY ANOTHER GM PRODUCT AGAIN I think its ridiculous I've had : water pump replaced @ 18000 miles, front axle seals replaced, drive shaft replaced, a/c control module, 3rd tail light leaking water into the cab, steering shaft replaced, steering shaft bushing replaced, instrument cluster replaced twice, and the most expensive transfer case replaced. ALL THIS WITHIN 53000 MILES!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!I HATE GM NOW!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!

175,519. No problem yet.

194,000 plus, 1 waterpump, M/A transfer case pump housing, and a set of donated upper A Arms, and the rest on the general's dime...I cannot complain!

Looks like I got it with 300,000 miles :D Do I get anything,like a qt. of oil

Looks like I got it with 300,000 miles :D Do I get anything,like a qt. of oil

Think you get the long distance award for sure.

http://gimg.dt00.net/goods/4189/418975/203321big.jpg (http://goods.us.marketgid.com/redirect/203321/)

Here's your quart. :D

i had 105,000 on mine before i took it apart to install merchant kit. on the inside, you could see where the pump was wearing through

Just got mine out found out it has a hole 123,000 miles.

Just noticed spots on the driveway and a wet under carriage, didn’t see a hole though, dry in that area, wet up front. 121K, ordered the Merchant kit & a seal kit. I'll pull it on Tuesday and see if it's official.

125,000 + and no issues yet.

No hole at 42500, but put the Kennedy plate in. Clip had fallen off so I dodged a major bullet!

It's official, found my hole! All the grime hide it well, only when some daylight hit it from the inside was I able to see it. After a little brushing you could see it well. The day after Thanksgiving I was eager to get it finished but everyone I knew that welded was closed for the long weekend. Jacka$$ me couldn’t wait so I found a certified welder on the internet who was open and could do it while I waited……..After putting a pound of new magnesium over the hole, he still could not stop the leak. I brought a bottle of alcohol with me to check the seal or lack of. Anyway it’s now Saturday and I need to wait for my guy to get back on Monday to see if he can fix it.

i dont have the pump rub..yet thats why i ordered the merchant automotive kit, and im gonna update it BEFORE i have an issue! plus they had a sale on the kit for $175 so i couldnt resist! but my question is can i remove the rear part of the t-case while in the truck? or will all the parts fall out as i seperate the case halves? (im assuming it would be a shower of heavy parts on my empty head) im just trying to find an easier way than removing the entire t-case, but if i have to remove it ... under the truck i go.

I have had my merchant plate for over 2 years and still havent installed it yet.

i had three holes in mine . Glad to have it fixed i dont know the mileage

i dont have the pump rub..yet thats why i ordered the merchant automotive kit, and im gonna update it BEFORE i have an issue! plus they had a sale on the kit for $175 so i couldnt resist! but my question is can i remove the rear part of the t-case while in the truck? or will all the parts fall out as i seperate the case halves? (im assuming it would be a shower of heavy parts on my empty head) im just trying to find an easier way than removing the entire t-case, but if i have to remove it ... under the truck i go.

If you go to Merchant's site, there's instructions for the install of the MA pumb rub fix...I can't see how anyone would be able to keep the t-case on the truck to install the fix. You will need to access the speed sensor hole on top as well. I removed mine to install the fix.

173,000 no hole

140k no hole

75k no hole so far.

104,000 no hole so far...

My hole developed at around 135K-140K as best I can tell. It was dry for a long time, JB weld and more fluid and it works. I'm still amazed that it works after that.

80,000 Hole.

Noticed oil on rear differential and exhaust. Quick JB patch that leaked in few days.

Removed t-case in driveway with front drive-shaft attached, degrease, JB Weld, 50.00 anti wear plate from Kennedy. 7000 miles so far, no leaks or problems.

I am new to the forum. 95,000 miles got a hole, I knew it was leaking, but i couldn't find it , til last night it was covered with oil and road grime .Taking the transfercase of today.

I am new to the forum. 95,000 miles got a hole, I knew it was leaking, but i couldn't find it , til last night it was covered with oil and road grime .Taking the transfercase of today.

Has anyone tried contacting Chevy/GMC and asked why this is not a recall?

john

Has anyone tried contacting Chevy/GMC and asked why this is not a recall?

john


That has been covered MANY times..........;)

That has been covered MANY times..........;)
....okay ...
And could you point me to a thread? In this thread?
thank you,,,

I can point you to the Search button at the top right side of the page,
I do not have the thread, but it is covered under one of the pump rub threads and I
have read it already, so do some searching around, it is in there I just do not know EXACTLY where.

Folks talked of class action law suits like the injector issue.

so what warranty covers pump rub? drivetrain?

3 yr/36K is what will cover it, unless you are like NJx72 who has friends who can hook you up for like a six pack of PBR and a Dill Pickle.

Just joined at 113k miles.

Not a club I wanted to be part of. lol

232000 no rub yet

45,000 miles and good so far. Let me ask this. Is it a factor of how many miles/hours one stays in 4x4?

45,000 miles and good so far. Let me ask this. Is it a factor of how many miles/hours one stays in 4x4?


Nope, pump housing is on the mainshaft, so it is always going to move but if you do alot of stop and go forward and reverse, then it will probably show sooner.

On the road guys do not see it as early if ever in some cases....

no hole yet with 193000 on 06 LBZ.

Thanks for the reply, Tolliwacker. I read your repair instructions (excellent) and MA's (again excellent), and I just need to decide whose fix kit I'll get. I'll definitely do a "pre-emptive" repair.

If no hole, go with the Riverside Gear plate, save the dough for something else.

If you want the cadillac of repairs, then go with the Merchant repair, and it comes with a Million mile warranty.

Good luck, and if there is anyway I can help, let me know!

140k , got me a hole

106k and no hole yet! :D

1st at 145,000 miles and the 2nd at 220,000 miles. Replaced the 1st at the dealership and JB Weld the 2nd. Lost my job in Aug so as soon as I get back on my feet I will replace the back half and put the rub kit in it this time.

140k no hole yet.

YOU are on borrowed time.

235,000 kms (~145,000 miles) and still going strong. I check it every oil change.

120k and no rub, gonna put the kit in this spring though

still no hole for me:lol:

156,000
Trashed and stuck in the snow bank!

112000 and no hole yet. plan on rebuilding the trans soon and will fix it then, hopefully before it wears through!

and this might be a dumb question but has anyone figured out why some people have this problem and others never do, or it just a coin toss?

I just pulled my case and went with Kennedy for the fix before it wore through. When I opened the case, the clip stuck to the pump housing and I found part of it on the magnet. There was some wear on the case, but not nearly enough to be a problem yet. I have 72k on it and it has had a plow on it all of its life. I suspect in another 40k +/- it would have worn through.

120k and no rub, gonna put the kit in this spring though
SO this sucks 2 weeks after posting this i got the hole..........

and this might be a dumb question but has anyone figured out why some people have this problem and others never do, or it just a coin toss?



Stop and go make it happen faster, over the road guys hardley ever see they rub....

Went 89K before the hole. Installed MA upgrade and have had no problems over the last 20k.

90000 miles I became a memberQ

111k before I noticed the leak. I fixed it with the Merchant Automotive kit. My only regret is that I believed those guys that said it only takes four hours. Hell, it took me that long just cleaning up the mess mess under the truck from the leaking DEX III. I also spent at least an hour trying to find a tool that worked for removing the bearing snap ring thru the case. All things considered though, I'm glad I did it myself.

180k before mine rubbed thru. Fixed with Merchant Auto kit and some JB Weld. No leaky or problems anymore.

Can the hole be welded shut once this has rubbed though? 112,000K and not sure if I should pull it and repair it with MA's fix.

53,000 miles I WILL NEVER BUY ANOTHER GM PRODUCT AGAIN I think its ridiculous I've had : water pump replaced @ 18000 miles, front axle seals replaced, drive shaft replaced, a/c control module, 3rd tail light leaking water into the cab, steering shaft replaced, steering shaft bushing replaced, instrument cluster replaced twice, and the most expensive transfer case replaced. ALL THIS WITHIN 53000 MILES!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!I HATE GM NOW!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!
I always love it when someone joins a forum just to bitch about their vehicle(s).

Where is that post, I willl offer him 100 bucks for his truck since he is so sick of it....

Will I joined the club yesterday on my 2000 sierra just turned 250,000.
My 2000 silveradoi has 240,000 and no rub yet.
My 04 duramax has 260,000 and no rub yet.

Just joined the club 95K miles......saw dirt sticking to case in corner, cleaned and JB welded for now will fix next time home.

Hello all, My truck just joined the club today at 71,250.0 miles.....needs a MA kit, case 1/2, etc. :(
Sir-Col

Clean and patch the case and save some dough!!!!!!!!!!!

I will post the part number of the two part epoxy I used, it is hard as woodpecker lips, the highway department uses it to glue in bolts into the highways. Unless you just gotta have the new case, up to you!

90k and mine was fine. Clip still in place and not broken, but the was some wear on it. I think it would have failed eventually. I am glad to have the piece of mind after having it in my thoughts for 2 years. I used the Kennedy fix. That damn snap ring was the only hard part. I had to make a custom tool out of an old set of needle nose to open it up far enough.

Thanks Tolli, I don't have to have another $300.00 expense, if in fact the epoxy will work. I would prefer to fix my case anyway, if at all possible, and if it will last. I will await your part numbers, Thanks a lot.
Sir-Col

Just turned 180,000 today on my 04 2500 HD LLY. No problem so far.

Thanks Tolli, I don't have to have another $300.00 expense, if in fact the epoxy will work. I would prefer to fix my case anyway, if at all possible, and if it will last. I will await your part numbers, Thanks a lot.
Sir-Col


I bought it at ACE Hardware, it was expensive like 25 bucks a tube, but I find MANY uses for it.

PC-Concrete injectible repair and anchoring epoxy
ASTM C881 = ASTM E488 =ASTM E1512

I assume those are numbers that may apply.

It came with 2 nozzles that have steps in it that mixes it while you squeeze it out. I tossed those, because it is just a waste of the stuff. When you remove the cap from the tube, you will see it has a divider because it is 2 part that comes out at once so I used a hammer handle and squeezed out the amount I needed and mixed it up on a piece of cardboard and applied it in between the webbing of the case half Thick, like 3/8" at least. Of course that is after scrubbing the case half and using brake cleaner to remove all the oils.

Been holding strong for 3 years now!

Good luck!

First pump rub at 120,000 miles. I did not take the time to do it right with the aftermarket fix. Decided to take to stealer and let them fix it. Big Mistake. They fixed it, charged me right at $1000 for new cover, labor and fluid. At 145,000 miles, yep, you guessed it, another pump rub hole in the new cover. Both holes were caught early, so the internal parts were still ok. Anyhow, I cleaned the hole with acetone, sanded, cleaned again and then put on JB Weld. Waited a few days, cleaned and sanded again, and second coat of JB Weld. That was about a year ago and 14,000 miles. No problems so far. $5.00 versus much more. I know it is not the proper fix; however, if it aint broke, dont fix it.

First pump rub at 120,000 miles. I did not take the time to do it right with the aftermarket fix. Decided to take to stealer and let them fix it. Big Mistake. They fixed it, charged me right at $1000 for new cover, labor and fluid. At 145,000 miles, yep, you guessed it, another pump rub hole in the new cover. Both holes were caught early, so the internal parts were still ok. Anyhow, I cleaned the hole with acetone, sanded, cleaned again and then put on JB Weld. Waited a few days, cleaned and sanded again, and second coat of JB Weld. That was about a year ago and 14,000 miles. No problems so far. $5.00 versus much more. I know it is not the proper fix; however, if it aint broke, dont fix it.

You caught the hole in time but the issue is still the clips inside that break. I'd keep checking for new holes as the pump rub will still occur101629

Here's a pic of the rear half of my t case which I replaced due to the pump rub...only one rub through hole but you can see a couple of wear points on the magnesium case.

I also used JB Weld with good results until I could install the Merchant fix to stop the rub.

108,000 and just found out today what "pump rub" meant. No hole yet...I'm going to have the Merchant upgrade done asap. I've spent enought money on the truck lately! I'll gladly spend a few hundred vs. a few thousand!!!!

a guy at work just called me because he's got oil over his back tailgate and can't figure out why. I told him sit tight i'll come down to the firehouse and i'll show him blindfolded where there is a hole. Sure enough, perfect pinhole. 125,000 miles, and i'll leave out of this post the words that came out of his mouth after I showed him the hole!!!

If anyone knows of a shop, in central Jersey that is familiar with this fix, please PM me. I can no longer get under the truck for heavy work.

had to replace t-case(something broke internally) at about 250,000 no holes

Many thanks to Tolli for a nice DIY write-up, and , it helped while repairing my pump rub this weekend. As you said, It was an easy job, and all in all.... I'm glad I did it my self. I was able to get the holes in the case tig welded closed, saved the case and $300.00, and installed the upgrade kit without any problems. Thanks again,:)
Sir-Col

:cool2:

80,000 miles no hole yet ( knock on wood)... the warranty runs out this june

dirtcheap,

is there a good LB7 diesel tech at the service department over there in P-cola?

And how picky are they on the injector special policy?

If you know that is.....any info would be great!

tolli, not to sure...i have done my best to keep it out off the shop at all costs... i just replaced the front hubs even though i got the warranty... they'd just blame the over sized tires... i havent had any trouble when taking it to the dealer ( knocks on wood) they've been pretty good to me but no real problems for them to fix either... im gonna take it in next month before the warrant runs out, ive got a small oil leak/drip at the bell housing( rear main, turbo oil line etc..) so we'll see how they handle it..

Just bought an 02 GMC 2500HD. Drove it home and found the pump rub hole before I even got the title switched over. Only 62,500 on the truck and from what I have learned from everyone's post it doesn't look like it just started. Nothing like getting the Cat just $hit in your mouth taste right from the start. JB Welded it for now. Will put the Kennedy in over the Holiday weekend.

Just bought an 02 GMC 2500HD. Drove it home and found the pump rub hole before I even got the title switched over. Only 62,500 on the truck and from what I have learned from everyone's post it doesn't look like it just started. Nothing like getting the Cat just $hit in your mouth taste right from the start. JB Welded it for now. Will put the Kennedy in over the Holiday weekend.


Yea I bought mine with the hole as well, and I laid under the truck looking for anything and everything out of the ordinary, saw the gunk buildup but thought it was just the usual till I found out otherwise.

I wrote a driveway direction and posted it in the DIY section a few years ago, here is a thread to it.

http://www.dieselplace.com/forum/showthread.php?t=140732

On post 70 is a link to Merchants mor detailed directions on tearing the case apart.

Good Luck!

Thanks. Any help is appreciated and I'm sure will come in more then handy. I will have a partner in crime when I attempt this. Hopefully we focus on the T-case and not the Fridge!

One question I do have is what kind of seal is inbetween the transmission and transfer case? Do this have to replaced when you do this job? If so can you get it from any autoparts store or do you have to go to the dealer for it?

One question I do have is what kind of seal is inbetween the transmission and transfer case? Do this have to replaced when you do this job? If so can you get it from any autoparts store or do you have to go to the dealer for it?

I got mine from the dealer....about $8. with tax.

I got mine from Merchant with the pump housing, the seal cost me like 5 bucks and I ended up NOT using it, so if someone wants mine, send me 5 bucks plus shipping!

I found mine around 145,000 K. The leak is stopped with some special seal stuff from a shop, but have not torn it appart to totally fix it. I wonder how long I can run it like this.

I ran over 10,000 miles on a 2 part epoxy patch, but the second thinest area is the top lub, it has been known to come through if no repair is made!

211,000 miles, no pump rub. Pulled transfer case today, replacing tail shaft bushing and installing rub fix anyway. Case was clean and full clip broke probably on the way out.

300,000 Miles when I had to repair it,so far no leak,did the in the truck repair :D
It is at 387,000 miles and the repair is holding :)

does the pump rub still happen on the 07.5 and up or did they fix it?

146K no hole but did the fix while tranny was out

It is at 387,000 miles and the repair is holding :)


What is the "in the truck repair"? I read through the whole thread and didn't see anyone reference I way to fix this in the truck unless you just JB welded the hole shut...

To install a fix, the case HAS to COME OUT.

JB Weld will buy you alittle time, but it is just eating another hole since there are 4 lugs on the pump housing.....

240,000 Km and a hole has appeared. Called GM and they denied there being an issue called pump rub claiming no one else ever called in. What I'd do for a list of issue numbers from all you who did call in. Throw that in their faces lying...... anyways, Do i have to move any cross members to pull this case?

Here are my instructions on how I did it in my driveway.

http://www.dieselplace.com/forum/showthread.php?t=140732

Nice your a saint thanks

I hit 113k before the hole showed up.

so has gm put something out that will not leak yet or will i have to replace it again last time it was under warranty and was on there dollar next time will be on mine

I have an 03 3500 DRW with 33,000 miles (sat for four years!).

I took it to Merchant Auto last week to have the pump replaced as preventive maintenance.

$440. now beats $2,000 later.

guess i better crawl under both trucks and look. 100k miles on mine and 223k miles on the parts truck... hmmm

I made it 108,000 miles before getting my hole.

130,00 ... it was an easy fix ... 4 hours and a Merchant Automotive Kit with Amsoil ... 20,000 miles later all is good

Just traded my 02 with 170,000 miles on it and never had the problem.

Just checked my transfer case and all still good. 227,000 on the odometer, but I've ran H2 tires/wheels since 2003 so actual mileage is 10% higher.

I do have a cracked front differential, from the 2003 manufacture date and driving in cold weather scenario. BAM!!

Okay, tonite I've verified I have now officially joined the "pump rub club"...thanks, GM. :(

So who has the highest mileage before the "hole"? I hit 196,000 km approx (or 118,000 miles) tonite.

In the meantime, time to find some JB Weld.

163,298 miles as of today, no issues. 2005 3500 Sierra SLT Crewcab. ;)

It all depends on
1 Stop and go driving
2 if the clip stays in ploace and does not move
3 if the pump housing does not cut throught the clip.

It is a crap shoot..................

Just did the merchant auto upgrade today and my clip was still like new hadnt been touched with 106,000 miles

Just did the Merchant pump upgrade at 111,500 miles. This was done as preventative maintenance. Clip still intact with no visible wear. For what it's worth... Been running Amsoil 5w30 Synthetic Tractor Hydraulic fluid (w/ overfill) since the first Tcase service at 30k miles. I know Eric doesn't endorse the the overfill, so draw your own conclusions. His kit is top notch!

250,000 km Hole is jb welded for now...parts on order
Guess i should fix my sig..its now a lbz

Merchant auto kit done today, 140,000 on mine, I am glad it is done and I am more glad I caught it in time.
Not much fun to do this fix alone

130,000 on mine and had been leaking i guess for a lil bit cuz i pulled the plug and no fluid in it :(

110k nothing yet, but Kennedy kit is in the mail

Got hole at 135,000 miles. JB weld and new fluid for now.

Located hole at 102,000 miles. Also did the JB Weld, new fluid....need to order pump rub kit. Christmas vacation job.

129K ...repaired...lastnight, drove the truck 45 min to work today and dry as a bone

MA kit put in @ 148k with no hole to be seen.

MA kit put in @ 148k with no hole to be seen.


How was the condition of the inside of the case?
Clip intact?
No indentation where the pump housing is banging on the area?

How was the condition of the inside of the case?
Clip intact?
No indentation where the pump housing is banging on the area?

I asked when I picked my truck up (had complete tranny built) and Eric/Nick told me the wear wasn't anything memorable or that stood out about the transfer case. The C3's though were an entirely different matter....:rolleyes:

188,000 miles

Went to change the fluid and didn't even get a Dixie cups worth of fluid out of it. :eek: No telling how long it had been like that. Filled up with 2 quarts and ran it down the road to flush it out and check for metal and had oil all over the underside of the truck when i got back to the shop with no visible seal leaks. :confused: Luckily no metal when i drained it. Didn't know anything about "pump rub" until i researched leaky transfer case on here.

JB Weld, back half of case and upgrade kit on order. Hopefully no internal damage when I get it apart.

Those of you that have been procrastinating, the kit is on sale right now.

Those of you that have been procrastinating, the kit is on sale right now.


Anyone who has not done this upgrade, should do it, and at this price!!!
DANG!!! There is NO WAY I would buy the flimsy plate over this Cadillac FIX!

Damg Eric! THAT IS CHEAP!!!!!!!!!!!!!!!!!

Black Friday Sale?

I should buy 2 just for shits and grins, and sell them to folks around here!

Visited my family for Thanksgiving and went to change the tcase fluid and appears that he has the whole. He has 140,000 miles. My truck has 130,000 miles and no hole. Temporary fix on dad's truck until permanant fix for xmas.

I had to have the syncro replaced in my transfer case at 104,000 miles. Engaging the 4 wheel drive above 20 miles per hour resulted in a horrendous clunk. While I didn't have a hole in my transfer case yet, the clip was almost worn through. I had the mechanic put the pump rub fix in while the transfer case was out. The clip is like a ticking time bomb. You have no idea when it will wear through the transfer case.

118t no hole, had the guys @ Shocker do the fix, Since I'm still recovering from hernia surgery. They also replaced my broken G80 at the same time.

Anyone who has not done this upgrade, should do it, and at this price!!!
DANG!!! There is NO WAY I would buy the flimsy plate over this Cadillac FIX!

Damg Eric! THAT IS CHEAP!!!!!!!!!!!!!!!!!

Black Friday Sale?

I should buy 2 just for shits and grins, and sell them to folks around here!

Yep -this pushed me off the fence and to a preventative repair.

Yep -this pushed me off the fence and to a preventative repair.


I paid 250 for it years ago, I am glad to see the price come down, it is now competitively priced with the flimsy riverside gear plate, for the extra 30 bucks, a person gets a Cadillac fix!

I know a couple more folks who bought the repair as well, since it is so low of a price!

Now no more worry!

Ok I just found out the I have the Pump rub. I only have 40k on it. Should that still be under warrenty?

This pole should be who has the pump rub with the least amount of miles. That would be a better indicator of when you may get 'rubbed'.

40 K is the lowest I have heard of..............so far

Pump rub kit and an Allison deep pan/transgo jr kit for Christmas this year! Merry Christmas to my truck :). Can anyone tell me which oil is highly recommended and how much transynd I'll need with the addition of the deep pan? Merchant deals look so good I'll prolly do the ss tierod sleeves to just because. Thanks for your input!
Preventative measures: 102,000 and running strong!

My 03 dually 133,000 miles..noticed it yesterday afternoon ( i have been watching it very closely for months)..Rolled it in the garage last night and found the very small hole about 2 oclock on the tailshaft housing..cleaned and jb quicked it...Fluid is fine..will roll again today.
I already have a anti pump rub ring in my garage..time to install it.!

My hole showed up at 246,000 miles a couple weeks ago. Putting in the MA kit right now . . .

Been watching closely, even bought the MA Upgrade a year ago. Sad to say although everything looked good Saturday, 300 mile trip Monday was enough to rub thru, drain and render case non rebuildable. Got 243,000 miles then boom, don't hesitate, it can happen quickly. I should have installed the kit when purchased instead of thinking I could wait.

It disintegrated your case in 300 miles?

I drove to Corpus Christi TX and back with a dry case, and halfway back it started makeing all kids of noises, but after the M/A install and a inspection inside, I put it all back together and it is fine!

I drove that truck at least 1700 miles dry, and I bet it was dry before that!

I am just saying WOW!

But hindsight is 20/20, I bet you wish you installed that kit!

Made it to 169000 before hole

Yes I wish I had followed thru on my original plan of prevention. I have learned more since last post. Under "What was I thinking?" I was mistaken to believe the Transfer Case was lubed from the tranny (actually I was told this and thought Allisons may be different than what I'm used to) so each time I checked the fluid I thought I was checking Case as well, so not sure how long I was running low. I park on gravel and there was no obvious mess under truck. ...... I highly recommend, not waiting to upgrade.
My donor truck had 54K on it, clip had dropped and wear had started but all is well now with Merchants Kit.

i want to positively i.d. my transfer case before I buy this ma fix. The ma website says these cases are affected: GM transfer case(model 136, 146, 246, 261, 261HD, 263HD, 263XHD, 261XHD)

All I see on my case is a sticker that says BZ5.

Can someone direct me to the proper identification of my case?

thanks.

There should be a round metal tag on the back of the case with numbers stamped on it. the first row will be your model number.

i want to positively i.d. my transfer case before I buy this ma fix. The ma website says these cases are affected: GM transfer case(model 136, 146, 246, 261, 261HD, 263HD, 263XHD, 261XHD)

All I see on my case is a sticker that says BZ5.

Can someone direct me to the proper identification of my case?

thanks.


You could use the fix...............

I just had mine done (preventitive) at 66,000 miles and had a slight amount of wear. The mechanic didn't need to take off the entire transfer case, just the back half-saving me some coin. Then he filled it with Transyd that he had left over from the transmission flush. It is a great feeling not to have to worry about an expensive fix down the road and having a more bullet-proof pickup. Thanks to Diesel Place for saving me some money in the long run!!!

Ask him HOW he got the rear case half off without removing the case.

It is 99.9% impossible, because the snapring holding the rear bearing has an access hole that is on TOP, so the case has to come out!

They are BSing you, I just hope at this point they actually DID the job.

But to be safe, I left a .1% chance of wiggle room for me to not have to eat crow.....

Yea, my truck got the hole right around 120,000. Wish I would have done the fix before I got the hole cuz I ended up having to buy a re-manned $1400 unit!

I had an issue at 85,000 mile. I was on a road trip and smoked the whole case. This should have been a recall. the best part is when you call chevy parts for info they don't have a clue. they told me to call General Motors. What a joke. Once you hear the grinding its too late to fix...