Transfer Case Clunk in 4LO

WARNING: This page is about a different car, the 2007 Isuzu i-370, 2007 GMC Canyon, and 2007 Chevrolet Colorado. 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 while in 4LO range only. Review the Symptoms - Transfer Case and perform the necessary inspections.
High/low planetary carrier assembly	Inspect for the following conditions: Excessively worn pinion gears The pinion gears loose in the planetary carrier Replace the high/low planetary carrier if any of the above conditions are found. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Annulus gear	Inspect the annulus gear dampener for being faulty. Refer to Cleaning and Inspection . Replace the annulus gear dampener, if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble . Inspect the tabs for the annulus gear in the front case for excessive wear. Replace the front case half, if worn. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Range sleeve	Inspect the range sleeve engagement teeth for excessive wear. Inspect the range sleeve to rear output shaft splines for excessive wear. Replace the range sleeve, if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Planetary carrier low gear	Inspect the fit of the planetary carrier low gear to the planetary carrier for excessive wear. Inspect the engagement teeth of the planetary carrier low gear to the range sleeve for excessive wear. Replace the planetary carrier assembly if the low gear is faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .