Three problems related to transfer case have been reported for the 2004 Chevrolet Suburban. The most recently reported issues are listed below.
Transfercase on suburuban began to leak around 80k miles when you put on lift you'll see little pin holes in the transfer case. This is caused by a faulty design where the pump rubs a hole from the inside of the t-case to the outside. Numerous companies have made a mod kit to address the issue which gm has not. You can put a temp bandage on it using jb weld but the case will need to be replaced.
Contact owns a 2004 Chevrolet Suburban. The vehicle switched into four wheel drive on its on.
2004 Suburban lt with 4 wheel drive. Occaisional loss of power when turning and accelerating into traffic. Usually lasts about two seconds before power returns. This is extremely dangerous when pulling into heavy traffic. Chevrolet has replaced the fuel pump , a timing device in the transmission and an air sensor over the course of six trips to the shop. I was told yesterday that this problem is known to gm engineers as the four wheel automatically sensing a need to shift , and that there was no known fix. I have and active complaint with gm, case number 1-269747819 since 10/21/2004.