03 2500HD blown transfer case, TPS wacky?

[Silverado2500HD03]

Hi Folks,

Vehicle is 2003 6.0 4x4 auto Silverado 2500HD

Apparently my transfer case had a small oil leak - not enough to notice a pool anywhere, but it ran dry and toasted the transfer case. Dealer wants a touch over 2,000$ to replace. I found a used unit nearby, but was wondering if anyone had or could direct me towards removal/installation instructions?

Any other helpful tips?

Annoyingly, shortly after the dealership called me to tell me that it was going to be 2,000$ to fix, they called back to ask me if I wanted to buy a new Silverado. You can guess my response.

Second, the truck intermittently goes into "Reduced Engine Power" mode, for no apparent reason. It could be directly after a cold start, or it could be when I'm driving down the highway at 70 mph with cruise on. All gauges read normal. The dealer suggested replacing the throttle body, but were unsure of the cause of the problem. I did a little reading on some of the forums and it seems as though the wiring harness to the TPS is the likely culprit. Again, any experience?

Appreciate the help.

Carter in RI

[newdad07]

Hey Carter,

Just found your post here as I was doing a little transfer case research. I have a 2003 silverado 1500 z71. It is in the shop today waiting on a rebuilt transfer case to be put in. My mechanic said it's going to be about $2000 as well, but approx. $1600 or so was the transfer case.
As he called around he has found that, it seems anyway, this problem is specific to 2003 chevy trucks. Apparently, GM revamped their transfer cases in 2004...which is odd cause 2003 was the body change, etc. I noticed you said you found a used transfer case to put on, so I guess just be careful you aren't getting one that's getting ready to go bad.

Apparently, what happened to mine was, the "core" inside my TC blew up and the parts inside started clanging around....my truck was sounding like the driveshaft was falling off. Eventually those parts flipping around in there wore two little pin holes in my TC and it started leaking fluid. The noise didn't start until just a few days ago though. Don't know if any of this applies to yours, so take that for whatever you want. If it doesn't apply, sorry for the long post....but if it saves you some trouble, it was worth it.

Good luck!

Chuck in Indiana

[j cAT]

Originally Posted by Silverado2500HD03

Hi Folks,

Vehicle is 2003 6.0 4x4 auto Silverado 2500HD

Apparently my transfer case had a small oil leak - not enough to notice a pool anywhere, but it ran dry and toasted the transfer case. Dealer wants a touch over 2,000$ to replace. I found a used unit nearby, but was wondering if anyone had or could direct me towards removal/installation instructions?

Any other helpful tips?

Annoyingly, shortly after the dealership called me to tell me that it was going to be 2,000$ to fix, they called back to ask me if I wanted to buy a new Silverado. You can guess my response.

Second, the truck intermittently goes into "Reduced Engine Power" mode, for no apparent reason. It could be directly after a cold start, or it could be when I'm driving down the highway at 70 mph with cruise on. All gauges read normal. The dealer suggested replacing the throttle body, but were unsure of the cause of the problem. I did a little reading on some of the forums and it seems as though the wiring harness to the TPS is the likely culprit. Again, any experience?

Appreciate the help.

Carter in RI

if you go with a used transfer case make sure that the fluid is blue ...if the fluid is dark gray or black or if looks like dextron III do not buy...



do not run a 4x4 in 4wd unless the ground is wet or icy..if you do these transfer cases will fail.. also auto 4x4 is not recommended to be used unless required....

replacement of the blue trac II fluid must be done when it begins to turn grayish...if not then you also will have this failure...I require this fluid change every 30-40,000mi...

if possible have a non dealer transmission shop replace used transfer case..



On your reduced power light check for proper voltage/battery/ connections, then get dtc codes to narrow down whats bad..it is a few items that could cause this, so need dtc codes..

do not go back to the dealer you mentioned, if necessary find another ...