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I have the same problem with my transfer case and I called the Simmons talk show on the radio and talked to the mechanics hosting the show they said that this transfer case has plastic forks in it and they get hot when it runs out of fluid and fail, it runs out of fluid due to a planned obsolescence design,they were well experienced in this problem said it is very common in these trucks and that I should definitely not use a rebuilt transfer case or a new gmc transfer case,because it would be the same problem all over again, I also believe this is well known to gmc, but just like Chevy to not stand behind there product and own there mistake, the host said that they used these inferior plastic forks to save costs in manufacturing the vehicle, just like gmc to plan the death of there own truck hoping that we will buy a new one when this one fails! Shame on you GMC! When it is time to replace this truck I will be more inclined to look at the other manufactures, and vote with my wallet! A transfer case should be built tuff, ths was not a cheap truck but they used cheap parts!
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