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Rear end clunk

Rear end clunk

Postby Mack in N.C. [OP] » Sep 19 2011, 5:11am

Just bought me a new(new to me) 2002 GMC Sierra 1500 4x4........
wow....nice truck........Havnrt had a truck in years....truck is still in its 30 day warranty when I informed dealer about clunk......after all my researching on this and other forums it looks like I have the classic rear end clunk Gm's are noted for.....fix looks to be nickle plated yoke ,,,,anyway my garage tells me it is not that it is my spline gears. He didnt look at rear end only just looked to see if drive shaft was tight.......

1. what are spline gears

2. everything i read is that it is the slip yoke....clunks when i take off from a stop.....how much does this cost to fix as I may get a rear end specialist to fix it instead of the deaker as the dealer is not a gm expert.

3. also, do i need to have the yoke replaced if that is the problem?....what is wrong with not replacing it......will not replacing it damage something else?

thanks for any and all replies......great site......Mack
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Re: Rear end clunk

Postby lzn197 » Sep 19 2011, 4:37pm

1. Spline gears? How about spider gears in the rear axle? Or splines on your driveshaft. I would tell the dealer thanks for letting me know what the problem is now FIX IT! Thats why I am HERE!!

2. Yes, slip yokes are a problem and when mine was replaced, ALL take off "thumps" were gone! Dealers dont like to replace them under warranty (used truck warranty) because the part was about 300 bucks!

3. If you get some of the special grease "spline grease" that GM used to have available, you can remove the driveshaft and grease it yourself. Anybody know that part number? Is it now available in the aftermarket?
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Re: Rear end clunk

Postby OlSmokie » Sep 20 2011, 1:18am

"Spline grease"? I haven't heard of that. I use regular grease and it only seems to last about 3 months. I was going to drill and tap the yoke for a grease nipple the next time I have it out. It is a pain in the rear to keep dropping the drive shaft but I'm getting good at it. :D
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Re: Rear end clunk

Postby lzn197 » Sep 20 2011, 1:30am

Oh brother. We are out of control. Good luck with the grease zerk idea.
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Re: Rear end clunk

Postby Z15 » Sep 21 2011, 3:25pm

If you get some of the special grease "spline grease" that GM used to have available, you can remove the driveshaft and grease it yourself. Anybody know that part number? Is it now available in the aftermarket?


Grease on the drive shaft flange is not recommended with 4x4 vehicles. ONLY USE ATF to lube the slip yoke. There is no shield that will prevent the grease from migrating into the transfer case, contaminating the fluid in the transfer case and leading to possible failure. There is cautionary service bulletin on this, the grease is only for use on 2 wheel drive vehicles which the drive shaft does not attach to the transfer case.

Subject: Do Not use Slip Yoke Grease from Bulletin #09-04-17-002C on 4WD Vehicles

--------------------------------------------------------------------------------
GM Customer Care and Aftersales


*URGENT - DISTRIBUTE IMMEDIATELY*


DATE: November 4, 2010
SUBJECT: Do Not use Slip Yoke Grease from Bulletin #09-04-17-002C on 4WD Vehicles.
MODELS: 2007 – 2009 Chevrolet Silverado 1500 Series

2008 – 2009 Chevrolet Avalanche, Suburban, Tahoe 1500 Series

2007 – 2009 GMC Sierra 1500 Series

2008 – 2009 GMC Yukon, Yukon XL 1500 Series

Equipped with 4WD (RPO NQG, NQH)

TO: Chevrolet/GMC Dealers
ATTN: Service Manager and Parts Manager

A new grease, part # 19257121 (in Canada, 19257122), was recently released for lubrication of slip yoke splines to repair a condition of a bump feel or clunk noise at stop or from launch on the vehicles equipped with 4L60 Automatic Transmission (RPO M30) and 2WD. Please see Bulletin # 09-04-17-002C for details.

Do not use the new grease for lubrication of slip yoke splines on 4WD vehicles. The output shaft in a 4WD transfer case does not have a grease retainer to keep the grease from migrating into the transfer case and mixing with the fluid inside. The new grease is not compatible with the Automatic Transmission fluid used in the transfer case and can cause damage if mixed. Lubricate the splines on 4WD vehicles with Automatic Transmission Fluid, P/N 88861003 (in Canada, 88861004). Please refer to Bulletin # 09-04-21-003B for repairing the bump feel or clunk noise condition on 4WD vehicles.


#09-04-21-003B: Clunk Noise at Stop or From Launch (Clean/Lubricate Rear Propshaft Slip Yoke Splines) - (Aug 11, 2009)


Subject: Clunk Noise at Stop or from Launch (Clean/Lubricate Rear Propshaft Slip Yoke Splines)


Models: 2007-2009 Chevrolet Silverado 1500 Series

2008-2009 Chevrolet Avalanche, Suburban, Tahoe 1500 Series

2007-2009 GMC Sierra 1500 Series

2008-2009 GMC Yukon, Yukon XL 1500 Series

Equipped with 4WD (RPO NQG, NQH)

Attention: This bulletin contains a procedure to clean/lubricate the rear propshaft slip yoke splines and replace, if necessary. Check the history on this vehicle. If the lubrication procedure has been performed previously, then continue on and replace the transfer case rear output shaft.

Condition:
Some customers may comment on a bump feel or clunk noise at a stop or on launch. Customers may also comment that the bump feel or clunk is noticed after the vehicle has come to a complete stop and that it feels as if the vehicle was bumped from behind.

Cause:
This condition may be caused by a slip/stick condition between the rear propshaft slip yoke and the transfer case rear output shaft splines. Braking to a complete stop can force the propshaft slip yoke forward into the transfer case while the vehicle rebounds slightly backward after stopping its momentum.

Correction:
Note: The clunk noise may also be due to fuel movement in the fuel tank when not completely full. If the condition is eliminated after filling the fuel tank, the noise is isolated to the fuel movement in the tank. Please make no repair attempts, as this noise is considered an operating characteristic.

Verify the customer's concern.

Clean/Lubricate Rear PropShaft Slip Yoke Splines
Remove the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI.
Inspect the rear propshaft slip yoke splines.
Note: Protect the transfer case rear seal from Brake Clean.

Clean the rear propshaft slip yoke splines with Brake Clean or equivalent and a shop towel.
Assure that the splines are free of rust or other foreign material.
Lubricate the spline with Automatic Transmission Fluid, P/N 88861003 (in Canada, 88861004).
Reinstall the rear drive shaft. Refer to One-Piece Propeller Shaft Replacement in SI.
Road test the vehicle and verify that the noise is gone.
If the vehicle has a repeat concern after lubricating the slip yoke splines, replace the rear output shaft.
Replace Transfer Case Rear Output Shaft
Note: Do Not replace the output shaft unless the cleaning and lubrication procedure is ineffective.

Remove the transfer case assembly. Refer to Transfer Case Assembly Replacement in SI.
Disassemble the transfer case. Refer to Transfer Case Disassemble in SI.
Replace the transfer case rear output shaft. Refer to the Parts Information below.
Assemble the transfer case.
Reinstall the transfer case assembly.

Parts Information:

19133059 - SHAFT, TRFER CASE (RPO NQH)

19133061 - SHAFT, TRFER CASE (RPO NQG)

88861003 (in Canada, 88861004) - Automatic Transmission Fluid


Note - These TSB do not cover prior year models because they are no longer under warranty.
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