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TRANSFER CASE CLUNK DURING ACCELERATION AND DECELERATION Cause Correction DEFINITION: A shudder, binding, or a crow-hop while turning, which may cause tire 1. Inspect the planetary differential pinion gears for the following conditions: Chipped, bent or deformed teeth Pinion gear bushings worn Pinion gear thrust washers missing Seized or binding pinion gears Refer to Transfer Case Cleaning and 2. Inspect the planetary differential for deformation. Refer to Transfer Case Cleaning and Inspection. 3. Replace the planetary differential assembly if faulty. Refer to Transfer Case Disassemble and Transfer Thrust washer 1. Inspect the thrust washer for seizure to the planetary differential. 2. Replace the thrust washer if faulty and the mating component if damaged. Refer to Transfer Case Planetary differential not 1. Inspect the planetary differential for being timed properly. Refer to Transfer Case Assemble. 2. Properly time the planetary differential gears. Refer to Transfer Case Assemble. Cause Correction DEFINITION: During acceleration or deceleration, a clunk is heard or felt in the transfer 1. Inspect the transfer case for the correct fluid level. Refer
2008 Chevrolet Silverado 1500 2008 TRANSMISSION Transfer Case - BW 4485-NR3 - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado
incorrect fluid to Transfer Case Fluid Replacement. 2. Inspect the transfer case for the correct type of fluid. 3. Flush the transfer case, and fill with the correct fluid, if required. Refer to Approximate Fluid Capacities. Excessive clearance 1. Inspect for the following conditions: Worn slip yoke splines Worn rear output shaft splines 2. Repair or replace the following components if faulty. Replace the slip yoke, if required. Refer to One- Replace the rear output shaft, if required. Refer to Excessive clearance 1. Inspect for the following conditions: Worn rear bushing Worn slip yoke bushing journal 2. Repair or replace the following components if faulty. Replace the slip yoke, if required. Refer to One- Replace the rear case half if the rear bushing is Worn or faulty planetary 1. Inspect the planetary differential for the following conditions: Loose planetary differential splines to the input Loose or faulty pinion gears Refer to Transfer Case Cleaning and 2. Replace the planetary differential assembly if faulty. Refer to Transfer Case Disassemble and Transfer
2008 Chevrolet Silverado 1500 2008 TRANSMISSION Transfer Case - BW 4485-NR3 - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado
TRANSFER CASE LEAK DIAGNOSIS Case Assemble. Worn or missing sun gear 1. Inspect to ensure the thrust washer is installed. 2. Inspect the thrust washer and mating surface for excessive wear. 3. Replace the worn or missing thrust washer. Refer to Transfer Case Disassemble andTransfer Case Worn or damaged rear sun 1. Inspect the sun gear external gear teeth for excessive wear. 2. Inspect the sun gear to rear output shaft for excessive looseness. 3. Replace the sun gear or rear output shaft if worn. Refer to Transfer Case Disassemble and Transfer Case Rear output shaft bearing 1. Inspect for the following conditions: Proper installation of the rear output shaft bearing Excessive wear or damaged retaining ring groove in 2. Repair or replace the following components if found faulty: Properly install a new rear output shaft bearing Replace the rear case half if the retaining ring Refer to Transfer Case Disassemble and Cause Correction DEFINITION: A visible indication of an external fluid leak from the transfer case. 1. Inspect for the correct sealer and the correct amount of sealer on the plugs.
2008 Chevrolet Silverado 1500 2008 TRANSMISSION Transfer Case - BW 4485-NR3 - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado
2. Install the plugs correctly. Refer to Transfer Case Fluid Replacement. Rear output shaft seal 1. Inspect for the following conditions: Overfilled or improper transfer case fluid Blocked vent Seal improperly installed, worn, or damaged Seal bore damaged or cracked Rear output shaft bushing for excessive wear Slip yoke seal surface for wear or pitting 2. Repair or replace the following components if found faulty: Adjust or replace the transfer case fluid. Refer to Clean, or properly route the vent hose. Replace the slip yoke if the surface could cause Replace the rear case half if the bushing is worn. Replace the rear case half if the seal bore is Replace the rear output shaft seal. Refer to Rear Front output shaft seal 1. Inspect for the following conditions: Overfilled or improper transfer case fluid Blocked vent Seal improperly installed, worn, or damaged Seal bore damaged or cracked 2. Repair or replace the following components if found faulty: Adjust or replace the transfer case fluid. Refer to
2008 Chevrolet Silverado 1500 2008 TRANSMISSION Transfer Case - BW 4485-NR3 - Cab & Chassis Sierra, Cab & Chassis Silverado, Sierra & Silverado
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