I have an klunk sound coming from the transfer case I think. It sounds like a bad U joint, but all seem to be tight. When truck is in neutral I can turn the driveline by hand and can feel some "slack" in transfer case. Not sure what is inside the Tcase. Are there some replaceable parts inside? Truck is a work truck and pulls a trailer most of the time, trailer weighs 10-12K depending on what is loaded.

No mods to speak of except new Fass DDRP LP, SouthBend clutch.
4x4, 112,000 miles

 

the only thing i can think of that might clunk in the T case is worn gears. There is a chain but it is only engauged in 4x4 to drive the front drive shaft.

there are some small parts inside like shiftfork pads. quad 4x4 sells a rebuild kit that should solve all the problems. around 575 bucks.

not to bad to tear into. couple of tricky areas to get back together, will test your patience.

 

Does it clunk when you are driving it, or putting it in gear?
if not dont worry about it

if it is check the splines on all slip joints the spline taking up the slack can cause quite a loud noise, and look closely at all U-joints they can appear/feel tight, but if you see ANY rust colored dust near the U-joints 100% certain that u-joint has failed

 

II am new to these forums let me now if I am posting in the wrong area.
I just bought 2001 4x4 manual trans and now the front axle does not engage.
the front shaft spins freely when in neutral 2 hi when in 4 hi the transfer engages I am assuming that I have a problem in front differential or front axle.
How should I troubleshoot this is there a shear pin in the front axle any info is much appreciated

 

front diff is vacuum accuated, could be a vacuum line unhooked, usually if a vacuum leak, cruise wont work and heater vents are stuck in the floor posn.

 

Thanks I will check it out.

 

Cruise control is working. Is it possible that I have a vacuum leak after the cruise control? Does the transfer case shift lever have an adjustment?
I noticed that the yellow 4x4 light does not come on during the start up wait. Is it supposed to light up. I would be highly botherated if the front axle would not engage just because a bulb is burned out.

 

Nope if the cruise no worky or front axle its probably a vacuum leak like previously stated. Allot of times the heater sticks on defrost only also with these systems.

 

So I was a little premature to ask what is in the Tcase. Found out they are rebuildable and there are kits out there, not sure which one is better than the other. After some more investigation, it is the slip yoke that is going bad. If I grab the slip yoke and wiggle it, there is some "play" in it, not much, but enough to make a considerable noise as it reverberates through the hollow drive line. I was told by a local shop that it is best to replace the whole driveline from the slip yoke on back. Does anyone have any experience with this? Any reccomendations on d-line upgrades? Thanks in advance.

 

The 4x4 lever will direct the vaccumn to the cad on the front axle. the switch may be bad on the transfer case. i think there are 4 lines on the switch.