Transfer Case Popping Noise

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.

Cause	Correction
DEFINITION: A faulty internal transfer case component that causes a popping noise in the transfer case. Review the Symptoms - Transfer Case and perform the necessary inspections.
Chain jump	Replace the chain and sprockets. Refer to Transfer Case Disassemble and Transfer Case Assemble in Transfer Case - NVG 263-NP1 Unit Repair. Replace the shaft bearings. Refer to Transfer Case Disassemble and Transfer Case Assemble in Transfer Case - NVG 263-NP1 Unit Repair. Inspect for damaged components caused by metal debris. Refer to Cleaning and Inspection in Transfer Case - NVG 263-NP1 Unit Repair.

Cause

Correction

DEFINITION: A faulty internal transfer case component that causes a popping noise in the transfer case.
Review the Symptoms - Transfer Case and perform the necessary inspections.

Chain jump

Replace the chain and sprockets. Refer to Transfer Case Disassemble and Transfer Case Assemble in Transfer Case - NVG 263-NP1 Unit Repair.
Replace the shaft bearings. Refer to Transfer Case Disassemble and Transfer Case Assemble in Transfer Case - NVG 263-NP1 Unit Repair.
Inspect for damaged components caused by metal debris. Refer to Cleaning and Inspection in Transfer Case - NVG 263-NP1 Unit Repair.