2nd Gen Non-Engine/Transmission And it goes clunk in 4wd

[tntframing]

When Im in 4WD I start to get a clunk from I think the front end, but it also feels like the rear end. It only happens in 4WD. Its like going over small bumps but theres no bump in the road. The vaccum motor is and has been broken, I rigged it so the front is always locked in. It cant be the vaccum motor, transfer case?, front diff?, axle? Any thoughs??? Thanks

 

[Cummins Thunder]

My 02 has always done the same thing. I think it is just slack in the drive line.

 

[Road Dog]

A certain amount of clunking is normal. The driveline tightens up because each tire is turning at a different rate. On loose surfaces (gravel, snow) the tires are slipping and releasing the driveline. On hard surfaces a tire has to break free. Plus the front and read diffs have different ratios -- 3. 54 front and 3. 55 rear (or 4. 10 front, 4. 11 rear).

(4WD is for OFFROAD/OFF PAVEMENT only. That's why it's called part-time 4WD. )

 

[tntframing]

I only use 4 wd in the snow and mud. In 5 years this is the first time this has ever happened. when it clunks i lose 4wd for a second Different ratios thats not possable i called the dealer and asked, they said different ratios would destroy the drive train

 

[Road Dog]

If the 4WD light goes out then I'd suspect the CAD or the vacuum lines that go to it (Even though you rigged it). I once had a line touch the exhaust and melt a small hole in the line. 4WD still worked; just not very well. The transfer case can clunk and pop out if it's not fully engaged but it won't engage on its own and you can see by the lever that something's happened.

 

[DKuykendall]

I have a posi lok cable and it will back in sometimes, mainly under load, then it clunks. Could your collar on the CAD be slipping off engagement?