Four problems related to transfer case have been reported for the 2004 Chevrolet Silverado. The most recently reported issues are listed below.
The contact owns a 2004 Chevrolet Silverado. The vehicle was taken to an independent mechanic for regular maintenance. The technician notified the contact that there was a hole within the transfer case and it needed to be replaced. The manufacturer was not notified of the failure. The approximate failure mileage was 118,000.
After an average cold night about 0 - 7* f, snow and ice were on the roads so the vehicle was parked in 4wd and left for the night, when I went to work the next day, the truck made a very loud growling noise from the front differential and trive train for about 20 - 30 miles. Turns out the front diif fluid is a standard 90w gear oil. The fluid froze causing damage to the transfer gears and locking up the right front axle cuasing the 4wd to not engage properly. Took to local dealer in kearney, mo and verified damage to gears and axle. Gm was contacted, and initially advised of no proplem repair. Dealer removed cover plate and found signifigant gear and axle damage, gm then replaced the whole front drivetrain assembly as it was under warranty.
I have a 2004 Chevrolet Silverado. I have had it to the dealer's service department (so far) twice and the first time they did not drive the vehicle so they stated they could not duplicate the problem. The second time the service tech rode with me and could hear the problem. They took the vehicle in and diagnosed it as "transfer case driveline growl". The dealer called Chevrolet/gm in detoit and was told that "there is not a correction@this time-no repair should be attempted".
While driving the vehicle on an icy road the 4 wheel drive system malfunctioned which caused the 4 wheel drive to engage automatically in 2 wheel drive.