NV236 Clunking
 

I recently changed my Transfer case fluid (NV236, Yes used Autotrack II). Im getting clunking in Auto, and 4hi. not in 2hi. Service 4WD light comes on and lights on my 4 button switch go out. Seems to be just staying in 4x4 and clunks during acceleration. My transfer case has 3 plugs, top one is the one with the Torx/ Allan and there are two other identical ones on the back. Bottom and mid way up. I drained all the old fluid out of the very bottom plug, then filled it untill it was up to the top Torx/Allan plug. used a hose with a manual pump to fill, but seemed like there where two different places to fill. directly above the hole for the plug, and if I fed the hose in further it seemed like there was a separate chamber. so filled the first till it started to overflow, then I could still put fluid it the further top portion without it flowing out of the plug.... After about 2 1/3 L of fluid I didn't add anymore. Did I do anything wrong?

did you read the manual to see how much its suppose to hold?

T case is over full. You should use just under 2qts.

would over filling it cause clunking? Should I just fill it to the plug 1/3 up? cause it's filled to the top Torx/Allan key plug @ the top.

Once it starts coming out of the fill plug that means its full.

A clunk can mean a lot of things. IS it coming from inside the tcase?

Have you checked the front shaft for play?

No front shaft play, but apparently I topped it up to the the Mode Fork plug, thinking it was the upper fill plug after reading on here that it was going to be a Torx/Allan style plug.....

Drained fluid to proper level (wasn't that over full) Still clunking, but may be from front axle assembly as well.

When does it clunk? when you turn? when you go a certain speed?

Does the front end lock?

It clunks when you take off, harder you take off the worse the clunk (Circular binding sound) Turning has no affect quiets down after 40km/h or so, or if I let off the gas. Maybe front axle vacuum actuator?

did you check the rear drive shaft?? maybe some universals.