Transfer Case Problems of Chevrolet Silverado 3500

Truck had a vibration in 4wd when accelerating since purchased new in September 2018. Found excessive metal on transfer case magnetic drain plug. After several warranty visits to multiple dealership service departments that denied any warranty issue existed, I paid out of pocket to have a reputable transmission company pull and open up the transfer case. The transmission company determined the transfer case had a manufacturing defect where a drive sprocket had been improperly spaced on the output shaft causing the 4wd chain to run at an angle destroying the chain and drive sprockets. Gm refused to admit any fault or pay for the repair on a vehicle with only 37,000 miles and a 5 year, 100,000 mile warranty.

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The contact owns a 2005 Chevrolet Silverado 3500. The contact stated that oil was leaking from the rear half of transfer case housing. The vehicle was taken to a private mechanic for inspection and the manufacturer was made aware of the failure. The vehicle was repaired. The failure mileage was 78,000 and the current mileage was 78,637.

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"service 4wd" error code shows up on dash display when driving through mud and water puddles, the vehicle enters 4wd before entering the mud/water but goes back to 2wd after being in the mud/water for a minute or two, also the 4wd push button light flashes when code is showing. After letting the vehicle dry out, the "service 4wd" error message does not appear. I need the 4wd all the time in the mud, not when it feels like working.

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Transfer case failed causing failure of slip joint and propeller shaft.

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