Cause
| Correction
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DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in the 2HI mode.
Review the
Symptoms - Transfer Case and perform the necessary inspections.
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Incorrect fluid level or incorrect fluid
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- Inspect the transfer case for the correct fluid level.
- Inspect the transfer case for the correct type of fluid. Refer to
Approximate Fluid Capacities .
- Flush the transfer case and fill with the correct fluid, if required. Refer to
Transfer Case Fluid Replacement .
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Excessive clearance between the slip yoke and the rear output shaft
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- Inspect for the following conditions:
• | Worn rear output shaft splines |
- Repair or replace the following components if faulty:
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Excessive clearance between the slip yoke and the rear bushing
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- Inspect for the following conditions:
• | Worn slip yoke bushing journal |
- Repair or replace the following components if faulty:
• | Replace the rear bushing if worn. |
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Input shaft thrust washers
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- Inspect for worn or missing input shaft thrust washers.
- Replace the thrust washers as required. Refer to
Transfer Case Disassemble and
Transfer Case Assemble .
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Worn high speed teeth on the high/low clutch
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- Inspect for worn high speed teeth on the high/low clutch. Refer to
High/Low Shift Components Cleaning and Inspection .
- Replace the high/low clutch if worn. Refer to
Transfer Case Disassemble and
Transfer Case Assemble .
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Rear output shaft rear bearing outer retaining ring
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- Inspect for the following conditions:
• | Properly installed rear output shaft rear bearing outer retaining ring |
• | Excessive wear or damaged retaining ring groove in the rear case half |
- Repair or replace the following components if found faulty.
• | Properly install a new rear output shaft rear bearing outer retaining ring. |
• | Replace the rear case half if the retaining ring groove is excessively worn. |
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