Clunk/gear grind going into 4WD HI

[Mattt]

Anyone else have it? It has done it as long as Ive owned the truck. Ive read the manual so I know the procedure for going into 4WD. Im usually not hard on the gas when I switch into 4WD, however no matter what I get a loud clunk & gear grinding noise going into 4WD high on the fly. Anyone know what's up with this, and how to prevent it? I cant imagine it being good.

[Shaners]

I had an '01 HD with the pushbutton 4WD. I had to have the entire transfer case replaced when the truck had less than 5K miles on it. There was no grinding when I engeaged 4-HI, but there was a terrible clunk and shudder that got increasingly worse the faster I was going when I tried to engage the 4WD.

 

I was without my truck for several weeks until they had the factory guys get involved. It ended up being a shaft in the transfer case that wasn't machined correctly.