I have a 2005 chev D/A and just replaced the t-case it clunks or bangs when going into 4x4. The old t-case made no noise like this when it was working properly. The shop that did the re&re is trying to tell my wife this is normal, I am away from home at this time so cannot drive this truck. Any ideas? This is our third D/A and none did this till now. Also do the 01 to 07 use the same transfer case. Thanks for any help or comments.

I have a 2003 D/A and it does the same thing when going into 4LO, but not 4HI. The manual even says that a noise and a bump or jolt is normal when going into or out of low range, but I don't think that's right for 4HI (mine is completely smooth).

I don't know if they use the same transfer case, someone else will have to fill you in there.

have you tried switching the ATF fluid to a 5w-30? i switched over in mine and it got rid of the slight clunk when i engaged it.

also make sure the slip yoke that come out of the tcase is well lubed. remove it and grease that sucker up. that will get dry and cause a clunk.

cured the problem put in a GM rebuilt t-case all is good

Hmmm....mine is not right then.....hasn't been for almost 55K. I get a good clunk and what sounds like some gear teeth/chain slack picking up slack when engaging into 4HI. I have noticed that once it's engaged it will not do it again next time I engage it on the same strip of road. I'm running 5w-30 and fluid is clean.

This is sad to say, but I haven't taken any notice to the driveline setup in this truck over the past 2 yrs of owning it. Does only the rear shaft have a yoke, or does the front also. Is the front shaft a CV joint or slip?

Hmmm....mine is not right then.....hasn't been for almost 55K. I get a good clunk and what sounds like some gear teeth/chain slack picking up slack when engaging into 4HI. I have noticed that once it's engaged it will not do it again next time I engage it on the same strip of road. I'm running 5w-30 and fluid is clean.

This is sad to say, but I haven't taken any notice to the driveline setup in this truck over the past 2 yrs of owning it. Does only the rear shaft have a yoke, or does the front also. Is the front shaft a CV joint or slip?


my truck is doing the exact same symptom as yours. Did you figure out what was the problem?

I spoke with Eric at MA today about this issue with my truck, and he feels it is the blocking plate that engages the gears up to speed that is worn on my truck. Has anyone else had this replaced on there truck?

I spoke with Eric at MA today about this issue with my truck, and he feels it is the blocking plate that engages the gears up to speed that is worn on my truck. Has anyone else had this replaced on there truck?

Got your PM today, I haven't done anything with it.

I am due to hopefully do a T-Case upgrade this year sometime and will tear into it then.

I was just curious if you ever did anything to remedy this problem? Did you change out that plate?