Clunking sound while in 4WD

Xysos

Xysos

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Supporting Member
Joined
Jun 16, 2020
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96
Location
Salida, Colorado
Hi all,

I am struggling to figure out the source of this clunking sound that occurs in 4WD. I am inclined to say transfer case (due to it only occurring while in 4WD). My only other guess would be the front axle or something between the t-case and front axle. This clunk is quite loud (video below in imgur link) and can even be felt from the cab.

I would greatly appreciate any help and please let me know if any pictures or other videos would help in determining the source of this clunk.

https://imgur.com/a/GtMpQ7t
 
I can't get any audio .... If it does it in rough terrain you need to look at how your suspension cycles and see if your track bar is hitting your skid plate to your gas tank or some other similar interference.

If it only does it when you're in four-wheel drive...check all your mounts and see if using four-wheel drive is creating stress on the system that two-wheel drive doesn't.

I know this is fairly vague but that would be my knee jerk reaction.
 
AndyG said:
I can't get any audio .... If it does it in rough terrain you need to look at how your suspension cycles and see if your track bar is hitting your skid plate to your gas tank or some other similar interference.

If it only does it when you're in four-wheel drive...check all your mounts and see if using four-wheel drive is creating stress on the system that two-wheel drive doesn't.

I know this is fairly vague but that would be my knee jerk reaction.
Click to expand...
The video starts muted so you will need to click on/ hover over and unmute it.

The sound only occurs in 4WD. I am new to working on my own vehicle. Could you elaborate on checking mounts/ looking for 4wd created stress or link to a thread that discusses it?

Thanks for your reply
 
Xysos said:
The video starts muted so you will need to click on/ hover over and unmute it.

The sound only occurs in 4WD. I am new to working on my own vehicle. Could you elaborate on checking mounts/ looking for 4wd created stress or link to a thread that discusses it?

Thanks for your reply
Click to expand...
Well first when you're in four-wheel drive nothing is really different than when you're in two-wheel drive except the fact that your drive shafts are now connected inside the transfer case at the chain.

The possibility of damage in the transfer case is possible but that's a little bit of an outside chance.... These transfer cases are extremely tough.

to restate what I'm saying everything that turns in four-wheel drive on the chassis is the same as in two-wheel drive it's a constantly active system but when you engage it in four-wheel drive you have changes inside the transfer case that make the connection.

The only thing that's really different as far as the drive line is it's now under load.... pulling.

There is a mount on the front of the transmission on the skid plate and you have your two motor mounts...something is either happening inside the transfer case or your four-wheel drive engagement is putting stress on something that doesn't get stressed in two-wheel drive like one of the mounts.
 
Could be that little green washer/ "O" ring on the T case lever not engaging or disengaging fully, if that's where the sound is actually coming from...My kid's T case ended up in pieces over 200 feet of highway because of that damn thing.

@AndyG check your PM's
 
Rubicon88 said:
4 lo and 4 hi?

Any noise whatsoever in 2wd?

Have you checked your front u joints? All of them. Yes all of them. Those are the simplest things to confirm or rule out first.
Click to expand...

Yes, in both 4 lo and hi. No noise at all in 2wd.

I have not checked the u-joints. What would I be looked for? Play in the u-joints or something else?

Thank you everybody for your replies.
 
Xysos said:
Yes, in both 4 lo and hi. No noise at all in 2wd.

I have not checked the u-joints. What would I be looked for? Play in the u-joints or something else?

Thank you everybody for your replies.
Click to expand...
As bad as that's clunking if you have a bad u joint it should be easy to find....but not always. Especially if its sitting still and you still have applied tourque to it. If you get all the tourque out....(reverse in two wheel drive...)and get the weight off the steering and front end (having the front in the air)

Shake the front driveshaft....use a prybar in the knuckles. If you've a bad joint you'll find it then.
 
Beadlejosh said:
Ever find out what the issue was?
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I never pinpointed it but I am still working on it. I am fairly sure it is a transfer case issue. I am pulling the tcase in the next week or two to take a gander. Haven't been offloading much so it hasn't been a priority
 
It’s been a while, so any update? I just got to OBX for some fishing and I ran into the exact same issue and sound as you had. And all my tools are 7 hours away from me while I’m here in Frisco. Sound only happens when the sand deepens and the drive train gets stressed. If it’s just the u-joint, I may be able to find a shop that can help, but they’ll curse the frozen cone bolts on my Clayton skids. I’m only here for three days, so it may be a wash out for me anyhow.
 
Nightrider7731 said:
It’s been a while, so any update? I just got to OBX for some fishing and I ran into the exact same issue and sound as you had. And all my tools are 7 hours away from me while I’m here in Frisco. Sound only happens when the sand deepens and the drive train gets stressed. If it’s just the u-joint, I may be able to find a shop that can help, but they’ll curse the frozen cone bolts on my Clayton skids. I’m only here for three days, so it may be a wash out for me anyhow.
Click to expand...

My transfer case ended up being on its last legs. Needed a rebuild or a replacement and I found a replacement for a reasonable price.
 
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Xysos said:
My transfer case ended up being on its last legs. Needed a rebuild or a replacement and I found a replacement for a reasonable price.
Click to expand...

Thanks for response. Unfortunately it’s not what I was hoping to hear. The double cardan would have been much easier (and less expensive).
 
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