Transfer Case Clunk during Acceleration and Deceleration

WARNING: This page is about a different car, the 2004 Oldsmobile Bravada and 2004 Buick Rainier. 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 when it is in AWD mode. 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.
Excessive clearance between the slip yoke and the rear output shaft	Inspect the slip yoke splines for wear. Inspect the rear output shaft splines for wear. Replace the slip yoke if faulty. Refer to Propeller Shaft Replacement - Rear in Propeller Shaft. Replace the rear output shaft if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble in Transfer Case - NVG 126-NP4 Unit Repair.
Excessive clearance between the slip yoke and the rear bushing	Inspect the rear bushing for visible signs of wear. Inspect the slip yoke bushing journal for wear. Replace the slip yoke if faulty. Refer to Propeller Shaft Replacement - Rear in Propeller Shaft. Replace the rear bushing if the bushing is worn. Refer to Transfer Case Output Shaft Seal Replacement - Rear .