03 2500hd. When I go to push the 4 hi button I get a loud clank, and when I use it in 4x4 the drivers side wont spin while in the mud. My cv shaft seems to be ok. Any ideas?

If your pulling through the mud and the drive train is under a torque condition , the truck will clunk or clank when putting it into 4wd high. Just traveling down the road and you hit the 4 high button , it should go right into 4wd with maybe just a click. The front end is a free floating drive, the wheel with the least resistance will spin first, if you turn the steering wheel back and forth , the drivers side should spin once in a while when torque is sent to that wheel. hope this helps you out, Charlie

I was at a transfer case shop that specializes in these cases and the mechanic said its the synchronizers in the cases. I think Eric Merchant sells a blocking ring kit that fixes it. Mine does the same thing, the mechanic explained that the ring or syncho whatever needs to allow the 2 gears to come up to speed gradually. When it is worn, the gears get slapped together too quickly which causes the grinding and thunking. He said as long as you don't need to shift on the fly, no biggie. I'll fix it when I do the pump rub, guess it's pretty easy.

I was at a transfer case shop that specializes in these cases and the mechanic said its the synchronizers in the cases. I think Eric Merchant sells a blocking ring kit that fixes it. Mine does the same thing, the mechanic explained that the ring or syncho whatever needs to allow the 2 gears to come up to speed gradually. When it is worn, the gears get slapped together too quickly which causes the grinding and thunking. He said as long as you don't need to shift on the fly, no biggie. I'll fix it when I do the pump rub, guess it's pretty easy.


I cant find the block ring kit

http://www.merchant-automotive.com/transfercaseblockingringkit.aspx

Bear in mind I haven't done this, just heard from multiple sources that this is what is causing the grinding and it makes perfect sense to me.:D

Wish we had a banging sound. I have an 08 HD and it will not engage in 4x4 - the dial light glows dull orange in both 2wd and 4x4. Snowing where I'm at and waiting for the dealer to call with a decision on how they are going to get it out of here. 21,200 miles on it and it just came from the dealer 3 weeks ago, had to replace diff, case, collars, 4x4 - everything. Entire 4x4 granaded, dealer said metal shrapnel throughout housing. Now, its not working again. Any suggestions?

http://www.merchant-automotive.com/transfercaseblockingringkit.aspx

Bear in mind I haven't done this, just heard from multiple sources that this is what is causing the grinding and it makes perfect sense to me.:D

Thanks

"03 2500hd. When I go to push the 4 hi button I get a loud clank, and when I use it in 4x4 the drivers side wont spin while in the mud. My cv shaft seems to be ok. Any ideas?"

I am also experiencing the front passanger wheel pulling hard when in 4-wheel going up a snow covered road. I've driven 4-wheel drive trucks quite a bit and I've felt each wheel pull a little more here and there as the previous poster explained, but never enough to have to turn the wheel the opposite direction to compensate for it. In this case, the more power I give the truck, the harder the passanger tire pulls, pulling the truck to the right, so I have to hold the wheel to the left. This does not seem right. I just had the top ball joints and tie rods replaces so I think the front end is tight. Had the front wheel bearings checked too and they were good I was told. I have 120k miles on a 2004.5 Chevy 2500HD 6.6 LLY motor. Lifted with 35" tires. Thanks for the help.