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Transfer Case Clunk in 4LO

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Transfer Case Clunk in 4LO

Cause Correction
DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in 4LO range only.
Review the Symptoms - Transfer Case  and perform the necessary inspections.
High/low planetary carrier assembly
  1. Inspect for the following conditions:
    • Excessively worn planetary gears
    • The planetary gears loose in the planetary carrier
    • Excessively worn range collar engagement teeth on the carrier

      Refer to Cleaning and Inspection in Transfer Case - NVG 261-NP2 Unit Repair.

  2. 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 - NVG 261-NP2 Unit Repair.
Annulus gear
  1. Inspect the annulus gear to front case fit for excessive looseness.
  2. Replace the front case half if the annulus gear is loose. Refer to Transfer Case Disassemble and Transfer Case Assemble in Transfer Case - NVG 261-NP2 Unit Repair.
Range sleeve
  1. Inspect the range sleeve engagement teeth for excessive wear.
  2. Inspect the range sleeve to mainshaft splines for excessive wear.
  3. Replace the range sleeve if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble in Transfer Case - NVG 261-NP2 Unit Repair.