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Discussion Starter #1
When I hit the button to shift into 4-wheel drive, the transfer case makes a rather loud clunk, seems to happen at any speed, coasting or under light throttle. Maybe it's normal, but my '05 Chevy gasser work truck is silent and smooth. Is there something that needs to be looked at?

Thanks,
Kacey
 

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YES! Have you noticed any oily film under the truck over the past year? Its a good possibility that you developed the TCase rubbing problem (pump inside case rubs case until theres a hole worn through, then all the fluid leaks out). Once the fluid is gone, the hard parts go fast after that. You're probably past the point where you can easily fix it.

You should check the fluid in the case. Even if its ok, there still coudl be something broken inside. Tcases shouldnt clank into gear.

Sorry its not something simple.
 

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Mine makes it all the time. First off, I am not sure if the transfer case is a 'shift on the fly' unit. If I remember my readings, you need to be slightly moving, under 5mph, and in neutral. You didn't say if you are getting the noise if you are shifting into low or high range.
 

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I'm glad I'm not the only one. I get the noise going into 4-high. You can shift into 4-high on the go, but not 4-low. There's no noise when I shift while stopped, so 4-low engagement is silent. The fluid is fine and I havn't had any leaks. I can shift my '05 gas 2500HD into 4-high at 45mph with no problems (Roads can get nasty in the winter here sometimes). Are they the same transfer cases?
 
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