I feel your pain! Can't imagine where that would be coming from??? I would carefully check the hoses. Worse case scenario??? Crack in head or block. For your sake, I sure hope not!
Took the transfer case motor off yesterday and tried turning the part in the new motor (using the dash switch and by hand) just a tad but wouldn't budge. (Old part does??). The transfer case shaft will turn but if the other won't, they won't match up since it only goes in one way. I had told my buddy when we had it all apart, if we "jury rigged" it by using a washer spacer to pull the splines out a bit maybe that would work. Tried it and quit clunking and stays in 4wd....for now. LOL
Last edited by doug Rooney; 01-18-2014 at 07:36 AM.
Reason: new info