Transfer Case Clunk in 2HI Only (1)

Transfer Case Clunk in 2HI Only Transfer Case Clunk in 2HI Only

	Cause	Correction
	DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in the 2HI 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	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. Propeller Shaft Front Slip Yoke Replacement
	Input shaft thrust washers	1. Inspect for worn or missing input shaft thrust washers. 2. Replace the thrust washers as required. Transfer Case Disassemble and Transfer Case Assemble
	Worn high speed teeth on the high/low clutch	1. Inspect for worn high speed teeth on the high/low clutch. High/Low Shift Components Cleaning and Inspection 2. Replace the high/low clutch if worn. Transfer Case Disassemble and Transfer Case Assemble

Cause	Correction
Rear output shaft rear bearing outer retaining ring	1. Inspect for the following conditions: Properly installed rear output shaft rear bearing outer retaining ring Excessive wear or damaged retaining ring groove in the rear case half 2. Repair or replace the following components if found faulty. Properly install a new rear output shaft rear bearing outer retaining ring. Replace the rear case half if the retaining ring groove is excessively worn. Transfer Case Disassemble and Transfer Case Assemble

Cause

Correction

Rear output shaft rear bearing outer retaining ring

1. Inspect for the following conditions: Properly installed rear output shaft rear bearing outer retaining ring Excessive wear or damaged retaining ring groove in the rear case half 2. Repair or replace the following components if found faulty. Properly install a new rear output shaft rear bearing outer retaining ring. Replace the rear case half if the retaining ring groove is excessively worn. Transfer Case Disassemble and Transfer Case Assemble