NHTSA Complaint #10461697 — 2004 GMC SIERRA

THE MANUAL SHIFT ON THE FLY SYSTEM (MSOF) WITH NEW VENTURE GEARS AUTOMATIC TRANSFER CASE IS DEFECTIVELY DESIGNED. A METAL ANTI-RATTLE CLIP WORKS IT WAY THROUGH THE CASE HOUSING, CAUSING ALL FLUID TO LEAK OUT OF THE TRANSFER CASE. THE CLUTCHES THEN BURN OUT RENDERING THE TRANSFER CASE USELESS. THE RESULT IS NO 4 WHEEL DRIVE (NO POWER TO FRONT WHEELS) WHEN SHIFT ON THE FLY IS PRESSED, LEAVING DRIVER SLIDING ON SNOW OR ICE--WHICH HAPPENED TO ME IN A NEAR WRECK. I RECOVERED FROM THE SLIDE AND GOT THE VEHICLE HOME AND THEN TO A REPAIR SHOP (ONCE THE SNOW MELTED) FOR A NEW TRANSFER CASE (REPAIR ONGOING). DRIVERS MAY RELY ON THE 4WD IN INCLEMENT WEATHER TO CERTAIN CONDITIONS AND BE INJURED WHEN THE 4WD DOES NOT ENGAGE DUE TO THE DEFECTIVE TRANSFER CASE. THIS CONDITION IS SO COMMON IN THE GMC SIERRA/CHEVY SILVERADO THAT THERE ARE NOW PARTS TO PREVENT THE CLIP FROM EATING THROUGH THE HOUSING: THE MERCHANT AUTOMOTIVE UPGRADE PROVIDES THE SOLUTION THAT SHOULD BE DONE TO ALL 4WD MODELS WITH THE DEFECTIVE TRANSFER CASES: HTTP://WWW.YOUTUBE.COM/WATCH?V=NJ5ZS8WOMNK&FEATURE=RELATED THE CONDITION WOULD NOT IMPACT 2WD MODELS, HOWEVER. IT SHOULD BE REMEDIED BY GENERAL MOTORS. *TR