Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system is operating properly.
Noisy in Drive
| Cause | Correction |
|---|---|
| Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement . | |
| Low gear oil level | Inspect the transfer case for leaks, repair as required. Refer to Transfer Case Leak Diagnosis , and Adhesives, Fluids, Lubricants, and Sealers . |
| Incorrect gear oil in the transfer case | Replace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers . |
| Water or contamination within the lubricant | Replace the lubricant and flush the transfer case of the contaminated fluid. |
| Loose propeller shaft mounting bolts | Inspect the bolts and replace and tighten, as required. Refer to Propeller Shaft Replacement . |
| Worn propeller shaft constant velocity joints | Replace propeller shaft assembly. Refer to Propeller Shaft Replacement . |
| Worn axle shaft constant velocity joints | Replace the constant velocity joints, as required. |
| Worn bearing in the differential assembly | Repair or replace the assembly. |
| Bearing noise within the transfer case A grinding noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A grinding noise that changes as a transmission shift occurs is not within the transfer case. A grinding noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A grinding noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires. | Inspect for the proper fluid level. Fill, as required. Identity the location of the noise using the CH-39570 Chassis Ears. If the noise continues, repair or replace the internal components, as required. |
| Gear set whine noise within the transfer case A whine noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A whine noise that changes as a transmission shift occurs is not within the transfer case. A whine noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A whine noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires. | Inspect for the proper fluid level. Fill, as required. Identity the location of the noise using the CH-39570 Chassis Ears. If the noise continues, repair or replace the internal components, as required. |
Noisy in Drive
Noisy When Coasting
| Cause | Correction |
|---|---|
| Inspect for the proper transaxle and gear oil levels prior to performing system diagnosis. Refer to Transfer Case Fluid Replacement . | |
| Low gear oil level | Inspect the transfer case for leaks, repair as required. Refer to Transfer Case Leak Diagnosis , and Adhesives, Fluids, Lubricants, and Sealers . |
| Incorrect gear oil in the transfer case | Replace the gear oil. Refer to Adhesives, Fluids, Lubricants, and Sealers . |
| Loose propeller shaft mounting bolts | Inspect the bolts and replace and tighten, as required. Refer to Propeller Shaft Replacement . |
| Worn propeller shaft constant velocity joints | Replace the propeller shaft assembly. Refer to Propeller Shaft Replacement . |
| Worn axle shaft constant velocity joints | Replace the constant velocity joints, as required. |
| Worn bearing in the differential assembly | Repair or replace the assembly as required. |
| Bearing noise within the transfer case A grinding noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case. A grinding noise that changes as a transmission shift occurs is not within the transfer case. A grinding noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A grinding noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires. | Inspect for the proper fluid level. Fill, as required. Identity the location of the noise using the CH-39570 Chassis Ears. If the noise continues, repair or replace the internal components, as required. |
| Gear set whine noise within the transfer case A whine noise that occurs at a specific engine speed, regardless of transmission gear, is not within the transfer case A whine noise that changes as a transmission shift occurs is not within the transfer case. A whine noise that changes as vehicle speed changes may be also caused by worn wheel bearings. A whine noise that changes as the vehicle turns may also be caused by worn wheel bearings and/or tires. | Inspect for the proper fluid level. Fill, as required. Identity the location of the noise using the CH-39570 Chassis Ears. If the noise continues, repair or replace the internal components, as required. |
Noisy When Coasting
New Product Information
The purpose of New Product Information is to document, important product changes which occur either model year-to-model year or interim model year.
Changes may include one or more of the following items
- Specification changes
- New sealants and/or adhesives
- Disassembly and assembly procedure revisions
- Mechanical and diagnostic procedure revisions
- New special tools required
- Interim model year design changes
- A component comparison from the previous model year
2008 Mid-Model Intermediate Drive Shaft (IDS) Seal Update
The IDS seal design was updated in the mid-model year 2008 Getrag 760/790 Transfer Cases.
Replacing the IDS seal with the correct seal requires identification between first and second design transfer cases. Refer to the table below.
| Seal Design Usage | First Design | Second Design |
|---|---|---|
| Transfer Case P/N | 24244573 | 24246665 |
| Original IDS Seal P/N | 19132951 / 19178698 | 19206322 |
| Original Seal Color | Yellow or Blue | Green |
| Replacement Service Seal | 19180998 | 19206322 |
| Service Seal Color | Green | Green |
| VIN Breakpoint: Chevrolet, Pontiac - 12/20/2007 | 2CNDL037686075818 | |
| VIN Breakpoint: Saturn - 1/2/2008 | 3GSDL43N58S631116 |
Scheme 32
First design, pre-breakpoint seals were built with IDS seals that have yellow or blue shaft guides and are replaced with unique, short neck seals (1) with a green shaft guide.
Second design, post-breakpoint seals were built with IDS seals that have green shaft guides (1) and are serviced with unique, long neck seals (2) with green shaft guides.
Seal Design
Second design IDS seals have sealing lips extended about 5 mm (0.20 in) from the first design sealing location.
Second design IDS seals are not compatible with first design transfer cases. Installing a second design seal in a first design transfer case will create a transmission fluid leak due to interference with the input shaft.
Scheme 33
Installing the replacement seal to the proper depth is critical. Use DT 48078 inner drive shaft seal installer with J 8092 driver handle to install the seal 2.8 mm (0.11 in) (a) from the end of the input shaft. Refer to Front Drive Axle Inner Shaft Seal Replacement .
Scheme 34
| Callout | Component Name |
|---|---|
| 1 | GM Part Number |
| 2 | Getrag Serial Number |