KZN185 driveline clunk on and off the gas

Hi All

99 surf in v good condition with 220Kkm on the clock. Always been well serviced by me.

So in normal driving (in 2wd), there is the usual amount of slight slack in the drivetrain between throttle on and off as you would expect. Now, when in 4wd (4wd button pushed in, Central diff lock not yet engaged - so basically "AWD" mode), there is a LOT of slack between throttle on and off e.g around a windy road, that quite obviously "thuds" somewhere in the drive train when I'm on and off the throttle.
It's a softish thud but quite noticeably a slack thud as if something is taking up a lot of movement between throttle on and off, and most noticeable as mentioned in the push button 4wd mode.

This is quite different from the slip joint thunk when stopping at lights (and I have a bit of that too!).

All unis excellent, Both driveshafts well lubricated. Rear diff has just been done with a locker and backlash is fine (and always was). Front diff dunno but seems all tight and good when in "proper" 4wd with the center diff locked in.
Engine mounts? I've check them and they seem fine. Pulled the rear transfercase mount completely out and it looked fine. Checked all bolts etc.
I'm an engineer and very aware of any issues in my truck - my mates in the 4wd club would probably say anal... However what I'm getting at is that I'm more aware than the average bear about maintenance and failures etc.

Are these transfers known for something like this? It really makes it impossible to drive on the road in mountain conditions where you would really like to have it in AWD mode. So much so that I'm wincing every time I get back on the throttle.

Ta all.

Matt
 
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Hi All

99 surf in v good condition with 220Kkm on the clock. Always been well serviced by me.

So in normal driving (in 2wd), there is the usual amount of slight slack in the drivetrain between throttle on and off as you would expect. Now, when in 4wd (4wd button pushed in, Central diff lock not yet engaged - so basically "AWD" mode), there is a LOT of slack between throttle on and off e.g around a windy road, that quite obviously "thuds" somewhere in the drive train when I'm on and off the throttle.
It's a softish thud but quite noticeably a slack thud as if something is taking up a lot of movement between throttle on and off, and most noticeable as mentioned in the push button 4wd mode.

This is quite different from the slip joint thunk when stopping at lights (and I have a bit of that too!).

All unis excellent, Both driveshafts well lubricated. Rear diff has just been done with a locker and backlash is fine (and always was). Front diff dunno but seems all tight and good when in "proper" 4wd with the center diff locked in.
Engine mounts? I've check them and they seem fine. Pulled the rear transfercase mount completely out and it looked fine. Checked all bolts etc.
I'm an engineer and very aware of any issues in my truck - my mates in the 4wd club would probably say anal... However what I'm getting at is that I'm more aware than the average bear about maintenance and failures etc.

Are these transfers known for something like this? It really makes it impossible to drive on the road in mountain conditions where you would really like to have it in AWD mode. So much so that I'm wincing every time I get back on the throttle.

Ta all.

Matt



My truck does the exact same thing. I've read somewhere it was normal with stick shift... Is yours 5speed or Auto?
 

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