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.

Incorrect fluid level or incorrect fluid

1. Inspect the transfer case for the correct fluid level. Refer to Transfer Case Fluid Replacement .
2. Inspect the transfer case for the correct type of fluid.
3. Flush the transfer case and fill with the correct fluid, if required. Refer to 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. Refer to One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement.

•	Replace the rear output shaft, if required. Refer to 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 One-Piece Propeller Shaft Replacement or Two-Piece Propeller Shaft Replacement.

•	Replace the rear case half if the rear bushing is worn. Refer to Transfer Case Assemble.

Worn or faulty planetary carrier

1. Inspect the planetary carrier for the following conditions:

•	Worn annulus gear

•	Worn or faulty pinion gears

•	Loose pinion gears

•	Planetary carrier to mainshaft splines for wear

•	Refer to Transfer Case Cleaning and Inspection.

2. Replace the planetary carrier assembly and annulus gear if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble.

Worn or missing sun gear thrust washers

1. Inspect to ensure the thrust washers are installed.
2. Inspect the thrust washers and mating surface for excessive wear.
3. Replace the worn or missing thrust washers. Refer to Transfer Case Disassemble and Transfer Case Assemble.

Worn or damaged sun gear

1. Inspect the sun gear external gear teeth for excessive wear.
2. Replace the sun gear or rear output shaft if worn. Refer to Transfer Case Disassemble and Transfer Case Assemble.

Rear output shaft bearing outer retaining ring

1. Inspect for the following conditions:

•	Proper installation of the rear output shaft bearing retaining ring

•	Excessive wear or damage to the retaining ring groove in the rear case half

2. Repair or replace the following components if found faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble.

•	Properly install a new rear output shaft bearing outer retaining ring.

•	Replace the rear case half if the retaining ring groove is excessively worn.