Transfer Case Clunk During Acceleration and Deceleration (1)

Transfer Case Clunk During Acceleration and Deceleration Transfer Case Clunk During Acceleration and Deceleration

Cause	Correction
DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case when it is in AWD mode. Review the Symptoms - Transfer Case and perform the necessary inspections.
Incorrect fluid level or incorrect fluid	1. Inspect the transfer case for the correct fluid level. 2. Inspect the transfer case for the correct type of fluid. Approximate Fluid Capacities 3. Flush the transfer case and fill with the correct fluid, if required. Transfer Case Fluid Replacement
Excessive clearance between the slip yoke and the rear output shaft	1. Inspect for the following conditions: Worn slip yoke splines Worn rear output shaft splines 2. Repair or replace the following components if faulty: Replace the slip yoke, if required. Propeller Shaft Front Slip Yoke Replacement Replace the rear output shaft, if required. Transfer Case Disassemble and Transfer Case Assemble
Excessive clearance between the slip yoke and the rear bushing	1. Inspect for the following conditions: Worn rear bushing Worn slip yoke bushing journal 2. Repair or replace the following components if faulty: Replace the slip yoke, if required. Refer to Propeller Shaft Front Slip Yoke Replacement. Replace the rear bushing if worn. – For light duty vehicles, refer to Rear Output Shaft Seal Replacement. – For heavy duty vehicles, refer to Transfer Case Disassemble and Transfer Case Assemble.