Three problems related to transfer case have been reported for the 2004 GMC Sierra 2500. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 GMC Sierra 2500 based on all problems reported for the 2004 Sierra 2500.
The contact owns a 2004 GMC Sierra 2500 hd. The contact performed routine maintenance on the vehicle and observed that the transfer case (4 -wheel drive) contained pinholes, which led to an internal fluid leak. The transfer case fluid level was completely empty. The locking clip failed, which contributed to the failure. The vehicle was taken to an independent transmission shop and the technician replaced the locking clip. The failure mileage was 120,000 and current mileage was 126,000.
Allison transmission housing failed at 54,000 miles. Gm paid parts, I paid 1,200. 00 labor , was told that there was 2 bulletins out on defective housing and when they finished repair they said they installed updated housing so I would not have problem again. Don't think I should have paid anything to have it repaired! at 105,000 miles transfer case failed , cost 1,150. 00 to repair, have had to take back 2 more times as repair was not done right. At 112. 000 miles speedometer became erratic was told it was a common problem ,and see on complaint search it is , consider this a great safety danger as I do not know what speed I'm going can only guess not fixed yet found some who sells rebuilt ones foe 150. 00 ,said their rebuilding them due the large number that are failing. Also at 112,000 miles park neutral switch started acting up ,check engine light on ,shift bar light goes away, truck won't shift properly and stay in certain gears without shifting up ,effects door locks. Looked up park neutral shift as part and came across bulletins stating that during left hand turn front tire sprays water onto park neutral ,switch causing problem ,needs front & rear shield installed to solve problem. Have taken truck back in waiting for information. Also around 90,000 miles had very hard time starting truck and truck ran poorly,problem became worse took in, fuel injectors were bad and were replaced under warranty at 112,000 miles no need to say I'm not a GMC fan anymore , even though I live in lansing mi ( a gm town)and have lots of friends and family employed there. Good by GMC! never again.
The contact owns a 2004 GMC Sierra 2500. While attempting to place the vehicle in reverse, the gear automatically shifted into neutral, causing the vehicle to coast backwards. Two days later, while driving at an unknown speed, the vehicle automatically disengaged out of two wheel drive and shifted into neutral. The vehicle would not accelerate so the contact safely pulled off the road and waited two minutes. He then pressed the button on the transfer case to re-engage the 4 wheel drive. He took his vehicle to the dealer and they replaced the transfer case control module and motor. There had been no further occurrences. The contact filed a complaint with the manufacturer. The failure mileage was 68,000 and current mileage was 68,268.