I'm about done...

davidbeaver1 · Apr 21, 2023

Here is my saga in short... 2005 Tahoe LT 4x4, 160,000 miles. Last September, transfer case started leaking, pump rub caused it, had transmission guy replace back half of transfer case with new and improved case and new pump guard. All good. 3 weeks later, transmission starts leaking fluid out of the shifter seals. Any time you get over 70 mph, starts leaking, and dripping on the cross pipe causing smoke. Back to the transmission guy to get transmission rebuilt. Got on this forum and got direction on how it should be rebuilt. It took until January to get all the parts and finally get it rebuilt. All good. 3 weeks later, going down the interstate and see smoke in my rear view mirror... What the... Ran by my trusted mechanic, he says transmission is dry, its oil from the oil pan gasket and valley cover. 3 more weeks it sits at his place while he replaces gaskets to stop all of the oil leaks. I get it back yesterday and take off for work 2 hours away this morning. About an hour and 15 into the ride, what do I see out my back window? Smoke rolling off my truck... I pull over and transmission fluid is everywhere! So I limp back home making sure to not go over 60 and stop by my trusted mechanic. He says that the transmission dipstick seal is where it is leaking from. Wouldn't you have replaced that seal when you rebuilt the transmission???

I'm about ready to trade this thing and get a Honda....

Sam Harris · Apr 21, 2023

davidbeaver1 said:
Here is my saga in short... 2005 Tahoe LT 4x4, 160,000 miles. Last September, transfer case started leaking, pump rub caused it, had transmission guy replace back half of transfer case with new and improved case and new pump guard. All good. 3 weeks later, transmission starts leaking fluid out of the shifter seals. Any time you get over 70 mph, starts leaking, and dripping on the cross pipe causing smoke. Back to the transmission guy to get transmission rebuilt. Got on this forum and got direction on how it should be rebuilt. It took until January to get all the parts and finally get it rebuilt. All good. 3 weeks later, going down the interstate and see smoke in my rear view mirror... What the... Ran by my trusted mechanic, he says transmission is dry, its oil from the oil pan gasket and valley cover. 3 more weeks it sits at his place while he replaces gaskets to stop all of the oil leaks. I get it back yesterday and take off for work 2 hours away this morning. About an hour and 15 into the ride, what do I see out my back window? Smoke rolling off my truck... I pull over and transmission fluid is everywhere! So I limp back home making sure to not go over 60 and stop by my trusted mechanic. He says that the transmission dipstick seal is where it is leaking from. Wouldn't you have replaced that seal when you rebuilt the transmission???

I'm about ready to trade this thing and get a Honda....

No offense intended here, but I might be looking for a new “trusted mechanic”. The vehicle will last you many more years, if properly cared for, assuming it’s not rotting out from rust. With 160k+, there are going to be a number of things needing replacement, but once done, and if done correctly, you’ll have a solid ride, and get the the point of standard / preventative maintenance.

OR VietVet · Apr 21, 2023

I feel for ya but I would say at least part of the problems is because of the "trusted mechanic". But, the transmission was at the mileage where they tend to cause problems and it sounds like the build went ok but the dipstick seal/o-ring was not replaced or is a defective new part or damaged during install. The dreaded transfer case rub problem is well documented. I am expecting to do the "whole shebang" one of these days, the transmission and transfer case at the same time.

I have a 2005 Z71 and love it and will continue to throw money at it because in the long run, it is more reliable and less expensive than a new rig. You need a heart to heart talk with the trusted mechanic or another mechanic that you research and use recommendations to find.

Or, buy a Honda and drive off in the sunset.

Rocket Man · Apr 21, 2023

So the dipstick didn’t install the dipstick correctly? There’s no seal except an o-ring on the dipstick tube which he would have seen if it was missing when he installed it. Dipstick.

mattbta · Apr 21, 2023

Rocket Man said:
So the dipstick didn’t install the dipstick correctly? There’s no seal except an o-ring on the dipstick tube which he would have seen if it was missing when he installed it. Dipstick.

davidbeaver1 · Apr 22, 2023

Thanks for your replies. Yeah I know, I'm just mad because as reliable as it has been, its left me stranded a couple of times now and that is frustrating. All of this started when I got the transfer case rear half replaced, It was due to pump rub as I stated earlier. Once I got that fixed, the transmission started puking oil out of the shifter seal and that led me to rebuild the transmission. I'm more inclined to think it is something the transmission guy did, not my trusted mechanic. What we found out yesterday afternoon was the transmission and transfer case both vent to a single vent tube. The vent was located right beside the dipstick tube and as it was pushing fluid out, it was running right down the transmission dipstick and making it look like it was running out around the dipstick seal. Now we know and have separated the vent tubes so we can determine which is actually pushing fluid out the vent tube. I have a funny feeling the transmission guy didn't do something correctly with the transfer case when he replaced the back half, at least that is my theory. I'm going to go run it up and down the highway today to see if I can recreate the issue and go from there.

I love this truck and I'm going to stick to finding out what the issue is. Thanks for letting me vent my frustrations here.

Rocket Man · Apr 22, 2023

You shouldn’t be losing fluid out of either vent tube unless the trans or transfer case is way overfilled. My suggestion is to check the levels of both before anything else.

davidbeaver1 · Apr 22, 2023

Both have been checked and both are at normal levels.

Alex_M · Apr 23, 2023

4l60e pump housing will sometimes not fully seal around the cavity leading to the vent tube causing fluid to get pushed out. This is the only spot in the tranny I will use RTV, and sparingly. Just enought to seal around that cavity. Not all shops do the same.

NickTransmissions · Apr 23, 2023

Alex_M said:
4l60e pump housing will sometimes not fully seal around the cavity leading to the vent tube causing fluid to get pushed out. This is the only spot in the tranny I will use RTV, and sparingly. Just enought to seal around that cavity. Not all shops do the same.

I have heard this as well but never seen it myself however ive seen rtv on the pump-case mating surface in a few 4l60E’s ive torn down over the years.

davidbeaver1 said:
Both have been checked and both are at normal levels.

Were any more leaks observed after you separated the drip hoses and drove it on the freeway?

I'm about done...

davidbeaver1

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Sam Harris

OR VietVet

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mattbta

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davidbeaver1

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