Cause
| Correction
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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 .
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Excessive clearance between the slip yoke and the rear output shaft
|
- 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
|
- Inspect for the following conditions:
• | Worn slip yoke bushing journal |
- Repair or replace the following components if faulty.
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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.
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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.
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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.
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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. |
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