DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in the 4HI 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 .
- Inspect the transfer case for the correct type of fluid.
- Flush the transfer case and fill with the correct fluid, if required. Refer to Capacities - Approximate Fluid .
|
| 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, if required. Refer to Propeller Shaft Replacement - Rear
in Propeller Shaft.
- Replace the rear output shaft, if required. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - BW 4482-NR4 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
- Repair or replace the following components, if faulty.
- Replace the slip yoke, if required. Refer to Propeller Shaft Replacement - Rear
in Propeller Shaft.
- Replace the rear case half if the rear bushing is worn. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - BW 4482-NR4 Unit Repair.
|
| Worn high speed teeth on the range sleeve |
- Inspect for the following conditions:
- Repair or replace the following components, if faulty.
- Replace the range sleeve if worn. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - BW 4482-NR4 Unit Repair.
- Replace the thrust washers, as required. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - BW 4482-NR4 Unit Repair.
|
| Worn or faulty planetary differential |
- Inspect the planetary differential for the following conditions:
- Replace the planetary differential assembly if faulty. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - BW 4482-NR4 Unit Repair.
|
| Worn or missing rear output shaft thrust washers |
- Inspect to ensure the thrust washers are installed.
- Inspect the thrust washers and mating surface for excessive wear.
- Replace the worn or missing thrust washer. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - BW 4482-NR4 Unit Repair.
|
| Worn or damaged rear sun gear |
- Inspect the sun gear external gear teeth for excessive wear.
- Inspect the sun gear to rear output shaft for excessive looseness.
- Replace the sun gear or rear output shaft if worn. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - BW 4482-NR4 Unit Repair.
|
| Worn or damaged front sun gear |
- Inspect the sun gear external gear teeth for excessive wear.
- Inspect the sun gear to drive gear teeth for excessive wear.
- Replace the sun gear or drive gear if worn. Refer to
Transfer Case Disassemble
and
Transfer Case Assemble
in Transfer Case - BW 4482-NR4 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:
|