For 1990-2009 cars

Cause | Correction
--- | ---
DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer case while in 4LO range only. Review the Symptoms - Transfer Case and perform the necessary inspections.
High/low planetary carrier assembly |

1. Inspect for the following conditions:

• | Excessively worn pinion gears

• | The pinion gears loose in the planetary carrier

2. Replace the high/low planetary carrier if any of the above conditions are found. Refer to Transfer Case Disassemble and Transfer Case Assemble.

Annulus gear |

1. Inspect the annulus gear dampener for being faulty. Refer to Transfer Case Cleaning and Inspection.
2. Replace the annulus gear dampener, if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble.
3. Inspect the tabs for the annulus gear in the front case for excessive wear.
4. Replace the front case half, if worn. Refer to Transfer Case Disassemble and Transfer Case Assemble.

Range sleeve |

1. Inspect the range sleeve engagement teeth for excessive wear.
2. Inspect the range sleeve to rear output shaft splines for excessive wear.
3. Replace the range sleeve, if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble.

Planetary carrier low gear |

1. Inspect the fit of the planetary carrier low gear to the planetary carrier for excessive wear.
2. Inspect the engagement teeth of the planetary carrier low gear to the range sleeve for excessive wear.
3. Replace the planetary carrier assembly if the low gear is faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble.