DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in the 4HI range only.

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. Refer to Approximate Fluid Capacities .
3. Flush the transfer case and fill with the correct fluid, if required. Refer to Transfer Case Fluid Replacement .

Input gear thrust washers

1. Inspect for worn or missing input gear thrust washers. Refer to Transfer Case Cleaning and Inspection .
2. Replace the thrust washers, as required. Refer to Transfer Case Disassemble and Transfer Case Assemble .

2/4 Wheel drive synchronizer assembly

1. Inspect the synchronizer for the following conditions:

•	The synchronizer hub internal teeth to mainshaft splines for excessive looseness caused by wear

•	The synchronizer sleeve engagement teeth to the synchronizer gear for wear

•	Refer to Transfer Case Cleaning and Inspection .

2. Replace the synchronizer assembly if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .

Worn high speed teeth on the range sleeve

1. Inspect for worn high speed teeth on the range sleeve. Refer to Transfer Case Cleaning and Inspection .
2. Replace the range sleeve if worn. Refer to Transfer Case Disassemble and Transfer Case Assemble .