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Transfer Case Clunk in 4HI

WARNING: This page is about a different car, the 2002 GMC Yukon XL, 2002 GMC Yukon, 2002 Chevrolet Tahoe, 2002 Chevrolet Suburban, and 2002 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.
Transfer Case Clunk in 4HI

Cause Correction
DEFINITION: During acceleration or deceleration a clunk is heard or felt in the transfer case.
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.
Worn high speed teeth on the range collar Inspect for worn high speed teeth on the range collar. Refer to Cleaning and Inspection in Transmission, Transaxle Unit Repair Manual.
Worn or missing input gear thrust washers Inspect for worn or missing input gear thrust washers. Refer to Cleaning and Inspection in Transmission, Transaxle Unit Repair Manual.
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