Transfer Case Clunk in 4LO

WARNING: This page is about a different car, the 2005 GMC Yukon XL, 2005 GMC Yukon, 2005 Chevrolet Tahoe, 2005 Chevrolet Suburban, and 2005 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

Cause	Correction
DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in the 4LO range only. Review the Symptoms - Transfer Case and perform the necessary inspections.
High/low planetary carrier assembly	Inspect for the following conditions: Excessively worn planetary gears The pinion gears loose in the planetary carrier The input gear for missing thrust washers or excessive thrust end play in the carrier Excessively worn range collar engagement teeth on the carrier Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the high/low planetary if any of the above conditions are found. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
Annulus gear	Inspect the annulus gear to front case fit for any looseness. Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the front case half if the annulus gear is loose. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
Range sleeve	Inspect the range sleeve engagement teeth for excessive wear. Inspect the range sleeve to mainshaft splines for excessive wear. Replace the range sleeve if faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.