I have worked out I have a 'clunk', only in 4WD, right under the centre console/middle of car (so guessing from Transfer case). When I first heard it I thought I'd broken something. But now I can nearly 'make it happen', if I use 4Low & drive up a really steep hill, then use heavy engine braking going down the other side (clunk), or shift into reverse and drive backwards up a steep incline (clunk), then when I start going back up a hill forward, one single 'clunk' again when it's gets pretty steep.
My best guess is a 'not quite tight enough' propshaft/driveshaft flange between the transfer case and the front diff. It's just 'that type of noise'. A single 'clunk' when the flanges rotate/slip until the bolts stop movement, and then going the other way, the 'play' is taken up again with a 'clunk' when the flanges rotate back the other way, until the bolts stop it.
Only happens under quite heavy load, so 4Low, 1st gear only. Can't ever recall it in 4Auto. Doesn't happen all the time, only under heavy load, so it must be holding fairly tight, just not tight enough for real high torque.
But it feels/sounds more like it's coming from the gearbox. Guess if it was the flange on the transfer case output, that would make it feel 'gearboxy'?
Anyone that experienced transfer case trouble care to describe what happened / how it felt?
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