DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in the 2HI 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.
- Inspect the transfer case for the correct type of fluid. Refer to Approximate Fluid Capacities
.
- Flush the transfer case and fill with the correct fluid, if required. Refer to Transfer Case Fluid Replacement
.
|
| 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:
|
| 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:
|
| Input shaft thrust washers |
- Inspect for worn or missing input shaft thrust washers.
- Replace the thrust washers as required. Refer to Transfer Case Disassemble (Light Duty)Transfer Case Disassemble (Heavy Duty)
, and Transfer Case Assemble (Light Duty)Transfer Case Assemble (Heavy Duty)
.
|
| Worn high speed teeth on the high/low clutch |
- Inspect for worn high speed teeth on the high/low clutch. Refer to High/Low Shift Components Cleaning and Inspection
.
- Replace the high/low clutch if worn. Refer to Transfer Case Disassemble (Light Duty)Transfer Case Disassemble (Heavy Duty)
, and Transfer Case Assemble (Light Duty)Transfer Case Assemble (Heavy Duty)
.
|
| Rear output shaft rear bearing outer retaining ring |
- Inspect for the following conditions:
- Properly installed rear output shaft rear bearing outer retaining ring
- Excessive wear or damaged retaining ring groove in the rear case half
- Repair or replace the following components if found faulty.
|