2003 Chevrolet Silverado 2500 Powertrain (other) Problems

The component that failed according to the Chevrolet dealer is the "transfer case pump clips", which came loose inside the transfer case and wore a hole through the case causing the oil to come out. If I would not have noticed the oil on the back of my truck, I could have continued to drive the truck, which could have caused the transfer case gears to lock up the front and rear axles while driving and could have caused me to wreck, causing injury to myself, my family or someone else. I marked the area of the leak with a sharpie as depicted in the photos.

NHTSA ID

11531325

Incident

Jun 28, 2023

I had to replace the replace the housing on my transfer case as it wore a hole in and was leaking. At a cost of 1200 dollars due to myself catching it early as later with a fully disabled case would have been 2600 dollars. My mechanic who deals in transmission repairs told me this a very common problem for Chevy trucks from 1999 to 2006. He claimed he had done 7 transfer cases in one week and was actually replacing a fully wrecked one for 2600 dollars as I brought mine in to be worked on . It had worn a hole through the transfer case and was leaking. As this seems to be a serious defect . I feel it should have been under a recall and reimbursement should be in order for those who paid out of pocket for repairs. My mechanic also stated that he has replaced them at 35, 000 miles and on up. No rhyme or reason to when they fail or leak.

NHTSA ID

11489023

Incident

Oct 7, 2022

TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 2500. THE CONTACT STATED THAT THE PUMP IN THE TRANSFER CASE OF THE TRANSMISSION FAILED. THE CONTACT STATED THAT THE FAILURE CAUSED A LEAK IN THE TRANSFER CASE WHICH ALLOWED THE TRANSMISSION TO DRAIN ALL THE TRANSMISSION FLUID FROM THE TRANSFER CASE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 163,000.

NHTSA ID

10760832

Incident

Aug 24, 2015

Mileage

163,000 mi

ON NOVEMBER 17, 2014, I WAS STOPPED IN THE MIDDLE LANE OF A HIGHWAY WAITING TO PULL INTO BUSINESS PARKING LOT, WHEN I ACCELERATED TO PULL IN, MY TRUCK MOVED FORWARD AND THEN WOULD ONLY REV UP THE RPM'S, ALMOST GETTING HIT BY ON COMING TRAFFIC ON THE HIGHWAY, I COASTED IN THE PARKING LOT, AS THE RPM'S WERE STILL UP, THE TRANSMISSION ENGAGED AND THE TRUCK MOVED FORWARD WITH A LOUD THUMP. LOCAL DEALERSHIP REPLACED A PART ($900) AND SENT ME ON MY WAY. ON DECEMBER 27, 2014 WHILE DRIVING AWAY FROM MY HOUSE, ONCE AGAIN THE ENGINE WOULD REV UP AND THE TRUCK JUST COASTED UNTIL IT ENGAGED CAUSING A LOUD THUMP. I CALLED AND LEFT MESSAGE WITH SERVICE WRITER. ON JANUARY 02, 2015, I WAS WITH 1/2 MILE OF MY HOUSE AND TRUCK WOULD NOT SHIFT, I WAS ABLE TO TURN AROUND AND DRIVE BACK TO THE HOUSE AT A VERY LOW SPEED KEEPING THE RPM'S LOW. TRUCK IS CURRENTLY AT LOCAL DEALERSHIP WAITING FOR MY APPROVAL TO REPLACE TRANSFER CASE WHICH HAS A PIN HOLE IN IT AND SOME OTHER PARTS FOR $3100. I REALIZE THAT PROBLEMS CAN HAPPEN WITH ANY MANUFACTURE, HOWEVER THIS GM ISSUE WITH A PINHOLE IN THE TRANSFER CASE THAT IS CAUSED BY AN INTERNAL PART THAT BREAKS AND DRIVERS LOSING POWER TO THE DRIVE TRAIN IS A REGULAR OCCURRENCE. I FOUND MANY FORUMS AND SOLUTIONS ON THE INTERNET AND ONE ON NHTSA. AFTER MARKET PARTS HAVE BEEN DEVELOPED TO REPLACE THE CHEAP PARTS WITHIN THE TRANSFER CASE TO PREVENT THIS FROM HAPPENING, UNFORTUNATELY I DID NOT RESEARCH THIS ISSUE PRIOR TO HAVING THE ISSUE. IN ADDITION, I CALLED A LOCAL REPAIR SHOP TO GET AN ESTIMATE FOR THE TRANSFER CASE REPLACEMENT, I WAS TOLD THEY REPAIRED THREE IN THE LAST TWO WEEKS AND TWO ARE IN THE SHOP FOR THE SAME PROBLEM. LOSS OF POWER TO THE DRIVE TRAIN IS NOT SOMETHING TO IGNORE, FROM PERSONAL VEHICLES TO PUBLIC SAFETY VEHICLES, THIS POWER LOSS COULD TURN INTO SOMETHING MUCH LARGER THAN SOME ATF STAIN IN THE DRIVEWAY. THANK YOU

NHTSA ID

10670468

Incident

Jan 1, 2015

Mileage

109,000 mi

TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 2500. THE CONTACT STATED THAT WHILE ATTEMPTING TO ACCELERATE AND MAKE A TURN FROM A STOP, THE VEHICLE STALLED WITHOUT WARNING. THE FAILURE RECURRED ON FOUR OCCASIONS. THE VEHICLE WAS TAKEN TO THE DEALER, WHO COULD NOT DUPLICATE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 60,000. THE VIN WAS NOT AVAILABLE.

NHTSA ID

10593171

Incident

Apr 18, 2011

Mileage

60,000 mi

VEHICLE WAS IN 4 WHEEL DRIVE, WHEN THE WHOLE TRUCK SHUTTERED, I LOST THE DRIVE CAPABILITIES OF THE TRUCK THEN STOPPED AND LOOKED UNDERNEATH VEHICLE TO FIND FLUID COMING OUT OF THE TRANSFER CASE. IN MY CASE THIS HAPPENED ON A RESIDENTIAL STREET, IF IT WOULD HAVE HAPPENED ON HIGHWAY IT COULD HAVE RESULTED IN A VERY BAD ACCIDENT. PLEASE CONTACT ME ON A POSSIBLE RECALL FOR THE TRANSFER CASE. UPDATED 12/01/2014 *JS

NHTSA ID

10592220

Incident

Feb 4, 2013

Mileage

142,318 mi

WHILE RETURNING HOME FROM A 2 WEEK VACATION (30 MILES FROM HOME) SLOWED DOWN TO MAKE A RIGHT TURN ON A CITY STREET IN WOODLAND, CA, THE TRUCK JUST SHUT DOWN, NO STEERING, NO BRAKES, NO ENGINE, TOTAL ELECTRICAL SHUTDOWN. IT WAS EVERYTHING I COULD DO TO MAKE THE TURN AND PULL TO THE RIGHT. AT THE TIME I WAS PULLING MY 2009 BIGHORN FIFTH WHEEL TRAILER. IT WAS A SCARY TIME. I FINALLY STOPPED, LUCKY THERE WAS NO CARS PARKED ON THE RIGHT NEAR THE CURB. I PUT THE TRANSMISSION IN NEUTRAL AND RESTARTED THE ENGINE. THEN WE CONTINUED THE TRIP HOME TO WINTERS, CA. I TOOK THE TRUCK TO IMLER DIESEL IN SACRAMENTO TO CHECK THE ENGINE OUT. THEY REPLACED THE INJECTORS WHICH WE HAD AGREED TO DO PRIOR TO MAKING THE TWO WEEK TRIP. THE NEXT TRIP WAS TO BODEGA BAY ON JANUARY 14, 2014. WE TRAVELED ABOUT 100 MILES. AGAIN WE WERE PULLING OUR FIFTH WHEEL TRAILER. SLOWING DOWN FROM 55 MPH TO 15 MPH, PREPARING TO MAKE A LEFT TURN IN DORAN BEACH PARK AT BODEGA BAY, THE TRUCK SHUT DOWN AGAIN.I CAME SO CLOSE TO HITTING A TREE. ONCOMING TRAFFIC STOPPED JUST IN TIME AS THE SPEED LIMIT AT 55 MPH SEEMED TO SEE WHAT WAS HAPPENING GIVING ME TIME TO RESTART AND MOVE OFF THE HIGHWAY. MY WIFE AND I WERE BOTH SHAKEN UP A BIT, BUT ALSO FEELING VERY LUCKY NOT HAVING A CRASH. WE CONTINUED HOME 4 DAYS LATER. WE PARKED THE TRUCK.THE MILEAGE WAS 143579 AT THE START OF THE TRIP AND 143819 AT END. I HAVE NOT USED THE TRUCK SINCE. I DO NOT FEEL IT IS SAFE TO DRIVE. I WAS LUCKY TWICE, DON'T KNOW IF I WANT TO RISK A THIRD TRY. LOOKING BACK, THE SHUTDOWN DID HAPPEN TWO OTHER TIMES BUT I WAS NOT PULLING THE FIFTH WHEEL TRAILER, I CAN'T REMEMBER THE DATES. CHEVROLET LT 2500 HD 4X4 DIESEL 2003 TRUCK. *TR

NHTSA ID

10568064

Incident

Jul 1, 2013

Mileage

143,416 mi

TL* THE CONTACT OWNS A 2003 CHEVROLET SILVERADO 2500 HD. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, HE NOTICED A TICKING SOUND FROM THE VEHICLE. THE NOISE BECAME LOUDER AND THE CONTACT LATER DISCOVERED THAT THE BEARING AND TIMING CHAIN WERE DAMAGED. ADDITIONALLY, THE TRANSFER CASE DID NOT CONTAIN ANY FLUID. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR FURTHER INSPECTION. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 195,000.

NHTSA ID

10567813

Incident

Feb 20, 2014

Mileage

195,000 mi

BEGAN HEARING LOW MOANING SOUND WHILE DRIVING DOWN HWY. PULLED OVER IMMEDIATELY TO DETERMINE CAUSE. FOUND TRANS FLUID LEAKING FROM ALLISON TRANS. TRANS. SHOP FOUND CRACKED EXTENSION HOUSING AND OLD METAL FRAGMENTS IN TRANS PAN. OLD METAL FRAGMENTS WERE CAKED INSIDE PAN INDICATING A LONG EXISTING PROBLEM AND NOT THE RESULT OF CURRENT CRACKED HOUSING. TRANS SHOP INFORMED ME THIS WAS A COMMON DEFECT IN THE CHEVY ALLISION TRANS, BUT WAS RARE IN VEHICLES WITH SUCH LOW MILEAGE (69000) AND WELL MAINTAINED LIKE MY TRUCK. INFORMED GM OF PROBLEM. GM DENIED ANY PROBLEMS WITH THE ALLISONS AND ARE REFUSING TO ASSIST IN RESOLVING ISSUE. CONTACTED ALLISON DIRECTLY AND WAS INFORMED THE TRANNY WAS ORIGINALLY DESIGNED BY THEM BUT IS MANUFACTURED BY GM AND THAT GM HAD MADE MODIFICATIONS TO THEIR DESIGN. THIS TRUCK ALSO EXPERIENCED $7000 WORTH OF FUEL INJECTOR ISSUES AT 50000 MILES. *JB

NHTSA ID

10542008

Incident

Aug 25, 2013

Mileage

69,100 mi

TRANSMISSION WOULD NOT ENGAGE INTO DRIVE FOR A MOMENT WHILE PRESSING ON THE GAS PEDAL. TRUCK WAS IN DRIVE AND WOULD ENGAGE AFTER A FEW SECONDS OF ACCELERATING. *TR

NHTSA ID

10521263

Incident

Jun 22, 2013

Mileage

117,000 mi

20030 CHEVY 2500 HD TRANSFER CASE WAS FOUND TO HAVE A HOLE IN TOP OF CASE. TOLD BY DEALERSHIP THAT IT WAS WORN FROM INSIDE OUT. THEY SAY THEY HAVE HEARD OF THAT AND GM DOESN'T WANT TO DEAL WITH IT BECAUSE TRUCK IS TO OLD. I HAVE 75,680 MILES ON TRUCK. *TR

NHTSA ID

10250999

Incident

Dec 5, 2008

Mileage

75,680 mi

CHEVY 2500HD YEAR 2003 I FILL A BUMP EACH TIME I STOP AND PUT OFF IN MY TRUCK. IT FILL LIKE SOMETHING IS ROLLING AROUND IN THE BED. I THINK IT IS IN MY DIFFERENTIAL OR DRIVE SHAFT. *TR

NHTSA ID

10228825

Incident

Feb 10, 2005

Mileage

160,000 mi

TOOK VEHICLE TO DEALER TWICE WITH COMPLAINT OF PARKING BRAKE NON FUNCTIONAL. ALLOWED TRUCK TO MOVE FWD. WHEN PARKED ON INCLINE,PRK BRAKE PEDAL FULLY DEPRESSED. SUPPOSEDLY BRAKES ADJUSTED TWICE,PROBLEM NEVER BETTER POST DEALER SHOP VISIT. TOOK IT TO PRIVATE SHOP. FOUND TO HAVE PADS SOAKED WITH DIFFERENTIAL FLUID FROM REAR END SEAL FAILURE. MOST PROBABLE CAUSE OF EMERGENCY BRAKE FAILURE. ON DISCUSSING WITH MECHANIC, HE MENTIONED THIS IS A KNOWN COMMON FAILURE ON THESE UNITS. PAID FOR REPAIRS MYSELF. NEVER SUBMITTED FOR WARRANTY REPAIR TO THE DEALER OR TO THE EXT. WARRANTY CONTRACT COMPANY (AUTOGAP XTEND). PROBLEM IS FIXED NOW. SEALS ,OLD PADS, REPAIR RECEIPT ARE IN MY POSSESSION. *NM

NHTSA ID

10136874

Incident

Mar 6, 2005

Mileage

54,000 mi

THE VEHICLE DOWN SHIFTED ERRATICALLY, WHICH CAUSED THE REAR WHEELS TO LOCK AND THE VEHICLE TO SPIN. *JB

NHTSA ID

10009254

Incident

Dec 15, 2002

Mileage

9,000 mi