I have a 2002 with 27,000 miles. Since DAY ONE with this truck, it has always exhibited a "clunk" when you engage 4WD, AND every so often, immediately after starting, the "SERVICE 4WD" light will show in the dash. It almost feels like the back end is catching upto the front end or vice-versa, and in the process, makes this clunking sound.

I took it to my dealer early on, and they said that nothing was wrong with, and it was "normal". They said that the 4WD message was caused by the fact the voltage was low (due to start condition), and it was throwing the SERVICE 4WD light.

I've never really thought anything about it, becuase it's always gone into 4WD. However, we just bought an '05 Tahoe, and it's VERY SMOOTH going into 4WD. My dad recently purchased an '02 D-max with 80K on the clock, and his is VERY SMOOTH going into 4WD.

I've seen the pictures of the thrust bearing that goes out in the transfer cases. I'm sure that I'll make it to 36,000 without incident. It's 45,000 that scares me. I'll be a little more than peeved if this thing goes out shortly after 36,000.

If I've got a case, I'd like to demand that my dealer do something about it.

Any insights???

Darrin

Mine (also an '02) does the same thing, has been since I bought it in August last year. Took it to the stealer, they told me they couldn't duplicate it, so the problem didn't exist. Grr. I don't have any problems with the 4WD working, though.

I wonder if it has anything to do with low fluid levels, or non-use? Maybe Eric or GMCSID or Patrick will chime in.

Tom

Not to be a worry wart, or anything, but I probably wouldn't worry about it too much IF I hadn't seen those pictures of wasted transfer cases. Couple that with the fact that my dad's is whisper quiet, and I've got issues. :)

A picture IS worth a 1000 words...

Darrin

have same problem here with my 02 silverado, the clunk when ingage in 4x4, and service light went on once, and just change trans case oil and axles, going to take to dealer see what they say, had 01 sierra and it was smoth switch

my 03 clunks when i engage, but ive never noticed the light coming on.