Transfer Case Clunk in 4HI. GMC Truck GMC K Sierra

For 1990-2009 cars only

Makes 🢒 GMC_Truck 🢒 2002 🢒 GMC K Sierra - 4WD 🢒 Driveline/Axle 🢒 Transfer Case - NVG 263-NP1 (Selectable) 🢒 Transfer Case Clunk in 4HI

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 .

•	Fill the transfer case to the correct fluid level, if required.

•	Inspect the transfer case for the correct type of fluid.

•	Flush the transfer case and fill with the correct fluid, if required.

Worn high speed teeth on the range collar

Inspect for worn high speed teeth on the range collar. Refer to Transfer Case Cleaning and Inspection in Transfer Case - NVG 263-NP1 Unit Repair.

Worn or missing input gear thrust washers

Inspect for worn or missing input gear thrust washers. Refer to Transfer Case Cleaning and Inspection in Transfer Case - NVG 263-NP1 Unit Repair.

Synchronizer clutch gear loose on the mode sleeve

Inspect the spline fit of the clutch gear to the mode sleeve for excessive clearance. Refer to Transfer Case Cleaning and Inspection in Transfer Case - NVG 263-NP1 Unit Repair.

Replace the clutch gear and the mode sleeve if the clearance is excessive. Refer to Transfer Case Assemble in Transfer Case - NVG 263-NP1 Unit Repair.

Synchronizer hub loose on the mainshaft

Inspect the spline fit of the synchronizer hub to the mainshaft for excessive clearance. Refer to Transfer Case Cleaning and Inspection in Transfer Case - NVG 263-NP1 Unit Repair.

Replace the synchronizer assembly and the mainshaft if the clearance is excessive. Refer to Transfer Case Assemble in Transfer Case - NVG 263-NP1 Unit Repair.