Transfer Case Clunk in 2HI Only
WARNING: This page is about a different car, the 2004 GMC Sierra, 2004 GMC Cab & Chassis Sierra, 2004 Chevrolet Silverado, and 2004 Chevrolet Cab & Chassis Silverado. However, it is still accessible from the selected car via links, so may be relevant.
Transfer Case Clunk in 2HI Only
| 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.
|
| Excessive clearance between the slip yoke and the rear output shaft |
- Inspect for the following conditions:
- Worn slip yoke splines
- Worn rear output shaft splines
- Repair or replace the following components, if faulty.
- Replace the slip yoke. Refer to Propeller Shaft Replacement - One Piece
and Propeller Shaft Replacement - Two Piece
in Propeller Shaft.
- Replace the rear output shaft. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - NVG 261-NP2 Unit Repair.
|
| Excessive clearance between the slip yoke and the rear bushing |
- Inspect for the following conditions:
- Worn rear bushing
- Worn slip yoke bushing journal
- Replace the slip yoke, if required. Refer to Propeller Shaft Replacement - One Piece
or Propeller Shaft Replacement - Two Piece
in Propeller Shaft.
- Replace the rear bushing if worn. Refer to Transfer Case Output Shaft Seal Replacement - Rear .
|
| Input gear thrust washers |
- Inspect for worn or missing input gear thrust washers. Refer to
Cleaning and Inspection
in Transfer Case - NVG 261-NP2 Unit Repair.
- Replace the thrust washers as required. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - NVG 261-NP2 Unit Repair.
|
| Worn high speed teeth on the range sleeve |
- Inspect for worn high speed teeth on the range sleeve. Refer to
Cleaning and Inspection
in Transfer Case - NVG 261-NP2 Unit Repair.
- Replace the range sleeve if worn. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - NVG 261-NP2 Unit Repair.
|
| 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. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - NVG 261-NP2 Unit Repair.
|