Transfer Case Popping Noise

	Cause	Correction
	Definition: A faulty internal transfer case component that causes a light popping noise in the transfer case. A light popping type noise that occurs when shifting, and quits after the shift is completed would be considered normal. When shifting out of 4 HI in a mode shift, there may be a delay and a popping may be heard when the HI/LO clutch disengages. 1. Compare the noise to a similar vehicle to see if a normal condition. 2. Identify the source of the noise using chassis ears and refer to the appropriate service manual section. 3. Note specifics such as when the noise is present (2HI, 4HI, OR 4LO). 4. Note if the noise relative to vehicle speed, is noisy on turns, or other specifics. 5. If the source of the noise is the transfer case, inspect for the correct fluid level. 6. Inspect the drain plug for large metal deposits. Small metal flakes and fine metal dust on the plug magnet are to be considered normal. Review the Symptoms - Transfer Case and perform the necessary inspections.
	Transmission or transfer case mounts loose or damaged	Repair or replace the mounts as required
	Propeller shaft center support bearing loose or damaged (as applicable)	Replace the center support bearing as required. Symptoms - Propeller Shaft
	Propeller shaft universal joints worn	Replace the universal joints as required. Symptoms - Propeller Shaft
	Suspension components worn	Replace the suspension components as required. Noise Diagnosis - Front Suspension or Noise Diagnosis - Rear Suspension
	Front axle actuator shift noise	Note: When shifting from 2WD-to-4WD or 4WD-to-2WD, the front axle actuator may be heard engaging or disengaging and the axle internal components shifting. This is to be considered a normal condition. Shift from 2WD-to-4WD and from 4WD-to-2WD to determine if the noise source is the front axle to determine if this is a normal condition.
	Transfer case drive and driven sprockets worn or a stretched chain causing a chain jump condition	Note: A chain jump condition may cause a banging noise and can only occur with the vehicle in 4WD. A chain jump condition may be caused by water intrusion into the transfer case and deterioration of the
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Cause

Correction

in extreme off road conditions or in situations where under-vehicle power washing occurs. 1. Inspect the oil for water intrusion and/or fluid discoloration and contamination. 2. Inspect the vent hose for proper routing and connection to the transfer case. 3. Inspect for damaged internal components. Drive Chain, Drive Sprocket, and Driven Sprocket Cleaning and Inspection 4. Replace the chain and sprockets as required. Transfer Case Disassemble and Transfer Case Assemble