Transfer case clucking

Took drive shaft to rebuilder today,

He said it's a Chinese model and the cardan joint and tail ujionts have lots of play,
So it's getting rebuilt and new spindles and sealed Spicer ujionts for 325.00 and will done tomorrow afternoon,
Looks like this might have been my problem even though it was a newer drive shaft

 

Got the rebuilt drive shaft installed and the sound is still there.
Did a little more testing and at 5mph when I push and let up in that 5mph I can hear the pop sound.

I put my foot on the brake not moving and I can feel and hear the pop in the stick shift now and NOT on the tcase shifter.

So now I'm thinking it's a transmission problem but have no idea what that would be, I did add the marlin short shifter 6 months ago

 

Ok, some we have 4 parts that could be causing the clunk.
1) drive shaft, just had it rebuilt.
2) rear diff, took it to two diff rebuilder and confirmed its working perfectly.
3) tcase
4) transmission,

Now that those 2 are eliminated I will drain the oil and see if I see and metal shaving.

I did some more trials on the tcase.

The clunk can be made whenever acceleration or deacceleration is done and when parked with emergency brake on going from 1st to reverse it clunk.

When parked with emergency brake on going from 1st to reverse it
1) clunks in 2 wheel drive
2) clunks in 4 low
3) in 4 high it DOESNT. clunk or a very slight clunk but 95 percent no clunk.

Could the 4x4 Actuator be causing clunk?

Knock has to be from tcase or transmission now.
Clunk is identical to a bad ujoint sound

 

Add the rear leaf springs into the mix of possibles. Inspect the three mounting points for each set of leafs for play or movement or in torque spec.

 

I had new OME springs installed two months ago and a locker diff that was installed by the dealership,
So everything is newer and just recently torqued down,

I can actually feel the knock in the transmission stick shift and the sound is coming from the the tcase- transmission area

 

maybe the rear (transmission) mount?

 

Did you figure this out? I'm going through the same issue

 

Yes, it was the 3rd member, backlash in the ring gear and pinion, was told it would be ok to drive but I got a low mileage 3rd member and now it's normal again no clunk

 

Thank you very much! I was told the third member was new in my truck but I'm thinking I should have it checked

 

It’s actually amazing how the sound travels, I could feel the the clunk in the shifter and the sound I swore was coming from the tcase or transmission. I almost replaced the tcase. I went to 4 different shops to get an inspection.
1) dealership sailed it was spider gears in dif.
2) independent axle rebuilder said is not the axle
3) another independent shop said not axle
4) independent 4x4 specialist said it’s the pinion gear and ring gear back lash.

after the 3rd member was removed when you rotated the ring gear you could hear the clunk