Cause
| Correction
|
DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case.
Review the
Symptoms - Transfer Case and perform the necessary inspections.
|
Incorrect fluid level or incorrect fluid
|
- Inspect the transfer case for the correct fluid level. Refer to
Transfer Case Fluid Replacement .
- Inspect the transfer case for the correct type of fluid.
- Flush the transfer case and fill with the correct fluid, if required. Refer to
Approximate Fluid Capacities .
|
Worn or faulty planetary differential
|
- Inspect the planetary differential for the following conditions:
• | Loose planetary differential splines to the input shaft splines |
• | Loose or faulty pinion gears |
- Replace the planetary differential assembly, if faulty. Refer to
Transfer Case Disassemble and
Transfer Case Assemble.
|
Worn or missing sun gear thrust washer
|
- Inspect to ensure the thrust washer is installed.
- Inspect the thrust washer and mating surface for excessive wear.
- Replace the worn or missing thrust washer. Refer to
Transfer Case Disassemble and
Transfer Case Assemble.
|
Worn or damaged rear sun gear
|
- Inspect the sun gear external gear teeth for excessive wear.
- Inspect the sun gear-to-rear output shaft for excessive looseness.
- Replace the sun gear or rear output shaft, if worn. Refer to
Transfer Case Disassemble and
Transfer Case Assemble.
|
Rear output shaft bearing outer retaining ring
|
- Inspect for the following conditions:
• | Proper installation of the rear output shaft bearing 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 bearing outer retaining ring. |
• | Replace the rear case half if the retaining ring groove is excessively worn. |
|
Worn or loose chain
|
- Inspect for a loose chain, excessive wear on the snubber, or deep gouges in the lining.
- Replace the chain, sprockets, and snubber. Refer to
Transfer Case Disassemble and
Transfer Case Assemble.
|