On slippery roads when i throw my 4wd in at speeds above 35 the front diff makes a noticable clunk noise and feel. almost as if the diff is coming apart. after that its fine. BTW this is with no power being given to the truck so no load

I think the general consensous is that it is normal....Mine has pretty much always done it. I just changed the fluid in my diffs and transfer case and it has gotten noticeably quieter. If you haven't changed your diffs in a while, I would do it. My front diff magnet looked like a chia pet. There were no big chunks on it just small shavings. Fluid looked pretty bad too.

On slippery roads when i throw my 4wd in at speeds above 35 the front diff makes a noticable clunk noise and feel. almost as if the diff is coming apart. after that its fine. BTW this is with no power being given to the truck so no load

Keep a constant foot on the throttle when engaging. If you lift then try to engage you will feel and hear a more noticable clunk.

When disengaging, take foot off throttle.

thanks i will try that

yeah my truck will do the same.. i flip it to 4hi when im stopped and then wehn i go i get the clunk. it sounds horrible, but i am guessing it is jsut normal for these trucks.
robert

IIRC the OLD manual on Chev K1500/3500 trucks C 1989-present MY mentions that when shifting Insta TracXfer case at any speed other than stationaryinto 4Hi, keep throttle position/speed constant. When selecting back to 2wd, take foot off of accelerator.