"AWD" Disengagement Clunk

An objectional "clunking" noise along with a slight jolt may be experienced after the "AWD" switch is turned "OFF". This condition could occur several minutes after turning "OFF" the "AWD" switch.

1. Make sure all the tires are inflated to the proper air pressure. Check all the tires for the same size, brand and similar tread wear. If tires are okay go to Step 3.

2. If tires are not alike, service as required. If the concern still exists after servicing the tires, proceed to Step 3.

3. Remove the rear halfshaft assemblies from the vehicle.

WARNING: DO NOT ENGAGE THE "AWD" FEATURE WHILE THE REAR HALFSHAFT ASSEMBLIES ARE REMOVED WHEN THE VEHICLE IS MOVING. THE VEHICLE MUST BE AT A COMPLETE STOP TO ENGAGE THE "AWD" FEATURE.

4. With the vehicle at a complete stop, engage the "AWD" feature by depressing the "AWD" switch to the "ON" position. Allow the vehicle to slowly roll forward for about 10 yards to make sure the "AWD" system is engaged.

5. Proceed to road test the vehicle at a steady posted speed while turning the "AWD" switch to the "OFF" position. If a "clunking" noise is heard three (3) seconds after turning the "AWD" switch "OFF", remove the transfer case and inspect for the following worn components:

^ Vacuum Motor Shaft
^ Shift Fork
^ Shift Collar
^ Clutch Splines (input shaft)

6. Replace any of the above components that are worn.