Cause
| Correction
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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.
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Incorrect fluid level or incorrect fluid
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- 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.
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Excessive clearance between the slip yoke and the rear output shaft
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- 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. Refer to
One-Piece Propeller Shaft Replacement and
Two-Piece Propeller Shaft Replacement.
- Replace the rear output shaft. Refer to
Transfer Case Disassemble and
Transfer Case Assemble.
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Excessive clearance between the slip yoke and the rear bushing
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- Inspect for the following conditions:
• | Worn slip yoke bushing journal |
- Replace the slip yoke, if required. Refer to
One-Piece Propeller Shaft Replacement or
Two-Piece Propeller Shaft Replacement.
- Replace the rear bushing if worn. Refer to
Rear Output Shaft Seal Replacement .
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Input gear thrust washers
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- Inspect for worn or missing input gear thrust washers. Refer to
Transfer Case Cleaning and Inspection.
- Replace the thrust washers as required. Refer to
Transfer Case Disassemble and
Transfer Case Assemble.
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Worn high speed teeth on the range sleeve
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- Inspect for worn high speed teeth on the range sleeve. Refer to
Transfer Case Cleaning and Inspection.
- Replace the range sleeve if worn. Refer to
Transfer Case Disassemble and
Transfer Case Assemble.
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Rear output shaft bearing outer retaining ring
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- 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:
• | Properly install a new rear output shaft bearing outer retaining ring. |
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