My brother's 2003 Chevy 2500HD had it's front axle gears disinigrate. It has about 1500 miles on it.

When he took it in, the dealer said that they had two other Chevy 2500HD trucks like it in the lot, and were waiting on parts.

It seems that they think that it was something to do with the oil from the factory, and when the 4wd was first engaged, it "turned" part of the aluminum housing, and went downhill from there...

Nothing was wrong with the transfer case, just the front axle.

Any thoughts?

- on edit: all three trucks came from different dealers, my brothers from another state.Edited by: conradv

synthetic in the front ends or not? Cold out when it happened? curious....

Stock fluid, winter - not really that cold. 20F degrees maybe.

Mine is at the dealer right now with a god awful front diff noise while in four wheel drive. Mine makes the noise at 30mph and aboe with my 5th wheel on it...or 60mph and above empty. It's been there for a week now, but I haven't gotten a straight answer about what they have found. FYI, mine has 12,000 miles on it..

hmm


Now that makes me wish I had tried the 4x4 on the 04 I test drove today at the dealer. I was going to but then got occupied. Is this a 03 thing only or other years have this problem as well? Not good either way...

Hmm, odd.


I towed the hell out of my truck in 4HI and all is fine. But it wasnt below 50F...

Been plowing in 4x4. No noises to speak of up there. 66,000 miles. I am running synthetic.

Could be some assy issues. Those axles are built by AAM and delivered to GM complete.

Mine is at the dealer right now with a god awful front diff noise while in four wheel drive. Mine makes the noise at 30mph and aboe with my 5th wheel on it...or 60mph and above empty. It's been there for a week now, but I haven't gotten a straight answer about what they have found. FYI, mine has 12,000 miles on it..

That's very similar to his, but it'll make noise (only in 4wd) at lower speeds. He saw one of the other trucks when at the dealer and the guy showed him the remains of the gears - looked nasty.

I got mine back today from the dealer. They said that the pinion was set too deep into the ring rear and hose the front diff. They completely rebuilt it, gears/bearings/seals. It seems fine now.

Makes me want to take mine in and say there is a noise, just to see what they come up with??? At low speeds it seems rough, but this is my first fullsize truck, so I am not use to any of the "regular" noises.