GLOBAL SAFETY FIELD INVESTIGATIONS
DCS5459
URGENT - DISTRIBUTE IMMEDIATELY
Date:

July 28, 2020

Subject: N202300240 - Customer Satisfaction Program
Transfer Case Leak
Models: 2019 Chevrolet Silverado 4500 HD / 5500 HD / 6500 HD
To:

All General Motors Medium Duty Dealers

General Motors is releasing Customer Satisfaction Program N202300240
today. The total number of U.S. vehicles involved is approximately 616.
Please see the attached bulletin for details.
Customer Letter Mailing
The customer letter mailing will begin on August 11, 2020.
Global Warranty Management (GWM)
The Required Field Action section on the Investigate Vehicle History (IVH) screen will
be updated July 29, 2020 or sooner. A list of involved vehicles in dealer new inventory
is attached to this message. Please hold all warranty transactions until IVH has been
updated.
END OF MESSAGE
GLOBAL SAFETY FIELD INVESTIGATIONS

Customer Satisfaction Program
N202300240 Transfer Case Leak
Release Date:
Attention:

July 2020

Revision:

00

ONLY Chevrolet Medium Duty dealers can complete this recall repair.
This program is in effect until August 31, 2022.

Make
Chevrolet

Model
Silverado 4500 HD/5500 HD/6500 HD

Model Year
From
To
2019
2019

RPO

Description

Involved vehicles are marked “open” on the Investigate Vehicle History screen in GM Global Warranty Management
system. This site should always be checked to confirm vehicle involvement prior to beginning any required inspections
and/or repairs.
Condition
Correction

Certain 2019 model year Chevrolet Silverado 4500 vehicles, may have a condition of a transfer case
fluid leak below the front input shaft bearing retainer or at the idler pulley bearing retainer.
Dealers are to inspect and if necessary, replace two o-rings on the transfer case.

Parts
Quantity
2
3
1

Part Name
O-Ring
40W full synthetic oil that meets SAE J2360 or Meritor 081 (Quart, Obtain Locally)
Loctite 242*

Part No.
19405791
NPN
19333511

*One container will service 24 vehicles. Order accordingly.
It is estimated that only 616 involved vehicles will require parts replaced. Due to the small number of vehicles anticipated
that will need this fix and the limited initial parts availability, dealers are encouraged not to order these parts for use as
shelf stock.
Reminder: Parts may be removed from Retail Inventory Management (RIM). Dealers should review the affected parts
to confirm RIM managed status. Parts may have quantity limiters in effect.
Warranty Information
Labor
Operation
9105159
9105160
9105161
9105162

Description
Inspect Transfer Case Serial Number
Replace two Transfer Case Bearing Carrier O-Rings (Includes
Inspection)
Customer Reimbursement Approved
- For USA and Canada dealers only
Customer Reimbursement Denied – For USA dealers only

Labor
Time
0.2
0.9

N/A
N/A

Trans.
Type
ZFAT
ZFAT

Net
Item
N/A
*

ZFAT

**

ZFAT

***

* The amount identified in “Net Item” should represent the actual sum total of the current GMCC&A Dealer net price for
SAE 40 W Synthetic Oil needed to perform the required repairs, not to exceed $30.00 USD.
Note: To avoid having to “H” route the customer reimbursement transaction for wholesale approval, it must be submitted
prior to the repair transaction.
** For USA and Canada: Submit the dollar amount reimbursed to the customer in Net/Reimbursement. Submit $20.00
administrative allowance in Net/Admin Allowance.
*** Submit $10.00 administrative allowance in Net/Admin Allowance.

Copyright 2020 General Motors. All Rights Reserved.

Page 1 of 10

Customer Satisfaction Program
N202300240 Transfer Case Leak
Service Procedure

5600859

This bulletin provides instructions for identifying and replacing the adjustable bearing carrier O-rings on MTC-3203AD02-100-300 model transfer cases. These procedures apply only to the forward output and idler adjustable bearing
carriers. These procedures apply only to MTC-3203-AD02-100-300 model transfer cases. Refer to TSB #16-NA-158:
U.S. Dealer Special Tool Loan Program for information on how to obtain the Front Output / Idler Bearing Adjusting Ring
Tool 13-191-01-02.

5600862

Note: Some vehicles may have chassis paint overspray on the transfer case identification label, making it difficult to
read. If this condition exists, verify the VIN is in the specified Special Coverage population. In addition, ensure the oil
leak is sourced from the idler and/or front output adjustable bearing carrier.

1. Locate the identification tag on the front of the transfer case.
2. Check and record the serial number on the transfer case ID tag.

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Customer Satisfaction Program
N202300240 Transfer Case Leak

5600868

3. If the serial number is between LRS01290649 and LRS01318770, proceed with the repair. If the serial number is
outside of the specified range, no further action is required. If an oil leak is present on a transfer case outside of the
specified serial number range, use SI diagnostic steps to repair the leak.
Note: If a leak is discovered, note which adjustable bearing carrier location shows evidence of the leak.

4. Thoroughly clean the rear side of the transfer case prior to any disassembly.

5600873

5. Using a 10mm Allen-head wrench, remove the magnetic drain plug from the front transfer case cover. Completely
drain the oil.
6. Clean the magnetic drain plug using a clean cloth. Using a 10mm Allen-head wrench, reinstall the plug and tighten
to 42-48 lbs-ft (57-65Nm).
Note: Only ONE adjustable carrier should be serviced at a time. Do not remove both at the same time.
Note: This step is to mark the orientation of the adjustable carrier to the case, so it can be installed in the same position
during re-assembly. The bearing preload is set by the manufacturer using the adjustable bearing carriers. It is critical
that the removed carrier is threaded back to its exact original location upon reassembly.

Page 3 of 10

Customer Satisfaction Program
N202300240 Transfer Case Leak

5600878

7. Beginning with the front output adjustable bearing carrier, mark the exact notch/position of the case and carrier
where the 13mm retaining flange bolt is located. With the carrier to case position marked, remove the retaining bolt.
DO NOT rotate the carrier until AFTER the reference mark has been made.

5600926

8. Using the back of a Vernier caliper depth gage, measure the distance the adjustable bearing carrier is standing off
the case surface. This measurement will be used as a secondary reference during the reinstallation to make sure
the adjustable bearing carrier is threaded back into the same location.
NOTE: Measurement must be obtained from the same location on the carrier/case upon reassembly.

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Customer Satisfaction Program
N202300240 Transfer Case Leak

5606757

9. Using special tool Front Output / Idler Bearing Adjusting Ring Tool 13-191-01-02 slowly begin to rotate the
adjustable carrier counter-clockwise while counting the full revolutions past your original starting mark.

5600930

10. Remove and discard the original O-ring from the adjustable bearing carrier.

5600931

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Customer Satisfaction Program
N202300240 Transfer Case Leak

5600932

11. With a clean cloth, clean and inspect the case bore and adjustable bearing carrier for any damage from corrosion or
debris.

5600933

12. Carefully install the new O-ring into the O-ring grove on the adjustable bearing carrier. Use a small amount of SAE
40W oil as a lubricant for reassembly.
Caution: Use care when installing the adjustable bearing carrier to avoid damaging the O-ring.
Note: You must count the rotations of the carrier during installation to return it to its originally installed position.

5606757

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Customer Satisfaction Program
N202300240 Transfer Case Leak
13. In the clockwise direction, carefully start the threads of the adjustable bearing carrier back into the case bore, using
caution to not damage the O-ring. Once the carrier threads are engaged with the case, begin to thread the carrier
clockwise while counting the rotations until the carrier stops rotating past your original reference mark. Note the
carrier will only rotate slightly past the original reference mark. At this time, the carrier should be positioned in the
preloaded state. Rotate the carrier counter-clockwise slightly until the original reference mark on the carrier is lined
up with the original reference mark on the case.
Note: Bearing preload is set by Meritor using the adjustable bearing carriers. It is critical to a proper repair that the
removed carrier is threaded back to its exact original location when installed.

5600926

14. Using the Vernier caliper, verify the carrier depth measurement is within 0.039in. (1.0mm) of the original reference
measurement. If the carrier is not within 0.039in. (1.0mm) of the original reference, remove the adjustable bearing
carrier and reinstall.

5600935

15. Apply a 3mm (.125 in.) of Locktite 242 around the retaining flange bolt threads approximately 6mm (.25in.) from the
end. Apply a 3mm (.125 in.) of Locktite 242 across the length of the threads.

Page 7 of 10

Customer Satisfaction Program
N202300240 Transfer Case Leak

5600878

16. With the bearing carrier in its original location, reinstall the flange bolt and tighten to 43-57 lbs-ft (58-77 Nm).
17. Repeat the exact same repair procedure for the adjustable bearing carrier at the idler location.
18. Using a 10mm Allen-head wrench, remove the transfer case fill plug and fill with new SAE 40W synthetic oil.
Reinstall the fill plug and tighten to 42-48 lbs-ft (57-65Nm).
Dealer Responsibility
All new, used, GM Certified Used, courtesy transportation vehicles, dealer shuttle vehicles, etc. in dealers' possession
and subject to this program must be held and inspected/repaired per the service procedure of this bulletin before
customers take possession of these vehicles. Involved vehicles must be held and not delivered to customers, dealertraded, released to auction, used for demonstration, or any other purpose.
All GM Certified Used vehicles currently in the dealers’ inventory within the Certified Pre-Owned Inventory System
(CPOIS) will be de-certified and must be held and remedied per the service procedure in this bulletin. Upon submitting
an accepted/paid warranty transaction in the Global Warranty Management (GWM) system, the vehicle can be re-certified
for sale within the CPOIS system, or once again be used in the CTP program.
Dealers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle,
or ownership, through August 31, 2022. Customers who have recently purchased vehicles sold from your vehicle
inventory, and for which there is no customer information indicated on the involved vehicle listing, are to be contacted by
the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this
bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program followup cards should not be used for this purpose, since the customer may not as yet have received the notification letter.
In summary, through August 31, 2022, whenever a vehicle subject to this field action enters your vehicle inventory you
must take the steps necessary to ensure the program correction has been made before selling the vehicle. In addition,
for vehicles entering your facility for service, you are required to ensure the customer is aware of the open field action
and make every reasonable effort to implement the program correction as set forth in this bulletin prior to releasing the
vehicle.
Dealer Reports
For dealers with involved vehicles, a listing with involved vehicles has been prepared and will be provided to U.S. and
Canadian dealers through the GM GlobalConnect Recall Reports or sent directly to export dealers. The listing may
contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor
vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in
several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to
complete this program.

Page 8 of 10

Customer Satisfaction Program
N202300240 Transfer Case Leak
Customer Notification
USA & Canada - General Motors will notify customers of this program on their vehicle (see copy of customer letter included
with this bulletin).
Customer Reimbursement
Customer requests for reimbursement of previously paid repairs to correct the condition described in this bulletin are to
be submitted to the dealer prior to or by August 31, 2021. See General Motors Service Policies and Procedures Manual,
Product Field Action Customer Reimbursement Procedure (USA & Canada) or local Policies and Procedures, for details.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of
conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained
technicians have the tools, equipment, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT
assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your dealer for information on whether your
vehicle may benefit from the information.

We Support
Voluntary Technician
Certification

Page 9 of 10

Customer Satisfaction Program
N202300240 Transfer Case Leak
August 2020
This notice applies to your vehicle, VIN: ________________________________
Dear General Motors Customer:
We have learned that your 2019 model year Chevrolet Silverado 4500 may have a condition of a transfer case fluid leak
below the front input shaft bearing retainer or at the idler pulley bearing retainer.
Your satisfaction with your Silverado is very important to us, so we are announcing a program to prevent this condition
or, if it has occurred, to fix it.
What We Will Do: Your GM dealer will inspect and if necessary, replace two o-rings on the transfer case. This service
will be performed for you at no charge until August 31, 2022. After that, any applicable warranty will apply.
What You Should Do: To limit any possible inconvenience, we recommend that you contact your dealer as soon as
possible to schedule an appointment for this repair.
Reimbursement: Because you have previously had this condition repaired, you do not need to take your vehicle to
your dealer for this repair. If you have already paid for repairs for the condition described in this letter, please complete
the enclosed reimbursement form and present it to your dealer with all required documents. Working with your dealer
will expedite your request, however, if this is not convenient, you may mail the completed reimbursement form and all
required documents to Reimbursement Department, PO Box 33170, Detroit, MI 48232-5170. The completed form and
required documents must be presented to your dealer or received by the Reimbursement Department by August 31,
2021, unless state law specifies a longer reimbursement period.
If you have any questions or concerns that your dealer is unable to resolve, please contact the appropriate Customer
Assistance Center at the number listed below.
Division
Puerto Rico – English
Puerto Rico – Español
Virgin Islands
GM Medium Duty Truck

Number
1-800-496-9994
1-800-496-9993
1-800-496-9994
1-800-862-4389

Text Telephones (TTY)

We truly appreciate you taking the time to remedy your vehicle as we know your time is valuable. We want you to know
that we will do our best, throughout your ownership experience, to ensure that your Chevrolet Silverado 4500 provides
you many miles of enjoyable driving.
Neelie O’Connor
Global Executive Director
Customer Experience Operations
N202300240

Page 10 of 10