Terrible clunking sound 233c 272 ratio Transfercase (VID)
 

Hello every 1 today i decided to check out my dads 4x4 in his 1997 s10 pickup

The truck sometimes has a hard time to engage as shown in the video
and has a horrible clunking noise in 4 lo and 4hi.

It will clunk worse when on the ground with pressure on it
The Clunk it coming from the rear of the shaft by the transfer case

Can it possibly be the transfer case ? or the cv joint on the end of the shaft
this >> More Information for DORMAN 932101

Here is the video thanks in advance guys

PICT1298.mp4 video by xgiovannix12 - Photobucket

Edit: Also what has to be done to remove the front shaft Just remove the clamps off the joint ? looks like it wont go any where

well your not into driveshaft yet at that speed. initial sounds is transfercase failing to engage. how many buttons you got? 4x4 light flashing when fails to engage right? secondly sounds like front axle not engaging fully, could be vacume is weak, bad cable, actuator??? whats not moving? what is rf wheel doing when t-case finally does engage?

The transfer case engages the 4wd works fine its when you put pressure on the tcase it clunks

it shows it engages in the video after a few trys

and it has 3 buttons

sounds like that shift motor or maybe the pivot it actuates going into the case is frozen the way it tries. its either that or the chain is skipping but i doubt it. if it was man the noise would be horriffic and constant. i would remove the shift motor and shift by hand and hold in and load it up to try again. sounds like its jumping out gear. i wish i were there to play with it but this should be pretty easy to diagnose. let me know if i can help anymore.

thats what i was thinking that the chain is skipping OR its the cv joint on the shaft

if you look closely by the cv joint when it stops it jumps

I was going to remove the shaft but i cant figure out how to remove it I did loosen the clamps for the joint but i cant get it to budge


tomorrow ill take an other video with the truck on the ground

it appears to do it worse when on pressure

sure itll jump cause the load shocking it. if u wanna pull it take the straps off pry the joint from the yoke with a bar and tape the caps so they dont fall off and lose the needle bearings. then the case ''snaps on'' tap gently forward on the joint and it will pop forward and slide off. it fit out of there but its tight. and make sure BOTH front wheels engage fully theres alot of ways these screw up and dont engauge fully

Ok thanks I do know the clunks coming from where the front shaft comes out

Who knows its prob isnt engaging all the way

Ill see what i can do thanks Im open to any other suggestions

hey guys i haven't checked the shaft yet but me and my dad had a conversation about this earlier

When the 4wd isnt engaged shouldn't the front shaft spin freely ?

well this one is still locked in

can it be its not fully engaging and disengaging ?

well i finally got into looking into this situation again

I pulled the shaft and the transfer case spins freely in 2wd ..
i found the front diffy locked .. I lifted the front of the truck and turned the flange where the shaft connects too and the wheels spined ...
I then pulled the vac lines off the transfer case and she disengaged .

I do still hear a sound while spining the tcase like the chain is moving in there but its not slipping

Im at a loss I think the vac switch is damaged


Edit: I took a video of the sound and also got the vac switch to free up... after engaging 4wd a few times it froze again .. Im going to be replacing that soon

This sound is just bothering me and it might be the cause of the original massive clunk i got in the 1st video
http://s1130.photobucket.com/albums/...t=PICT1654.mp4

Im open to any opinions guys

wow. i have no idea. if its doing it while your spinning the front output then its in the transfercase obviously. might not be a bad idea to see if you can find a used one and just replace it.

a few times ago when i took my truck out i catastrophically destroyed my transfercase, it was banging kinda like yours then i eventually lost my front wheel drive and it still banged around in 2wd. got it home, tore it apart and found not a dang thing wrong with it, it had one broken little bearing type washer.

im not familiar with the internals of these transfercases, i dont know if theres guides or bearings that could be bad, or maybe some kinda fluid pump. sorry cant be much of a help.

basically if it was me id just replace it or drive it til it blows up