My truck has been doing it for a while but I was stupid and chose to ingore it except for putting new fluid in it. When I am moving at all and put it in 4wd the transfer case clunks (it sounds like gears clashing)and goes right into 4wd. The 4wd works perfectly otherwise (I made 7 passes at Indy drag racing I just put it in 4wd when I am not moving)and like I said I put some new synthetic fluid in it and it still does it. It used to not do it and my dads truck doesn't do it either so I am trying to figure out what I need to do. Has anybody else experienced this and or what should I do.

Mine does it too, but it doesn't have anything to do with the 4wd. Whenever I push on the pedal at a stoplight it clunks and if I am on the highway and I let off the pedal and throttle it again, it clunks. Drove by my favorite dealership and the tech took a quick ride with me. He said it was my transfer case and it won't cause me any trouble except for annoyance. He said that he has seen it a lot with high mileage 3/4 ton trucks. He told me when I get some time and some money, he will fix it.

Have you checked the tailshaft mount of the trans near the Crossmember?

Mine does not clunk any more.

That mount needs to be solid..... otherwise it is a noticeable clunk. Approx 3 times louder than a U-Joint clunk yes?

I'd start there first on the mounts and make sure all are tight.

It's not just a clunk it more of the sound of gears clashing. I'll check the other stuff though just to be sure.

Mine has had clunk/excess freeplay from new (haven't done many kms yet) similar to what Tel9000 describes. Checked the rear mount - all tight. I would be interested to know what a Tech would do to the transfer case.

Likely rebuild it.

Mine made the same sound, my whole transfer case was destroyed when I eventually got the dealer too look inside (3- tries). Got a whole new one under warranty.

mine does the same thing, turns out the whole t-case is shot, can get a 1-year warranty remanufactured unit in Tulsa, Ok for 895.00 plus 400.00 labor.

Scott C,

Was your issue the same as BigBlackdMax or my issue? I have my vehicle serviced from time to time in Tulsa and which shop has that transfer case deal? Thanks.