Re: 2002 chevy 2500 hd 4x4 clunk sound in front end only...
Take it easy! Years ago i had a brand new GM and the front diff bolts came lose and just about put my head through the windshield But it is probably the CV joints the ball get dried out.
Have replaced left/right hub ***, and cv joint (half shaft) on driver side front u joints alsoHave replaced left/right hub ***, and cv joint (half shaft) on driver side front u joints also
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No hubs on 2002 Chevy 2500. I'd check the front axle actuator (engages front axle when 4WD is engaged). Belive it's on the passage side axle tube of front differential. Could be wrong, but that's what it sounds like. Or the front ring/pinion is shot. They don't turn when not in 4wd.
remove the drive shaft then remove the brake hoses and e brake cables remove the breather hose then remove the bolts at the springs or links which ever it has
http://www.compnine.com try this web site they have very detail break down picture of the front end of your truck build your model of your truck and look in group number 6.000 front axle front suspension - steering
First verify that your drive shaft universal joints are not worn out. You can do this if you can raise the truck and place it on jack stands and block the front wheels to prevent movement. This takes the load off the drive shaft. Rotate your drive shaft CCW and CW by hand to check for any play in the universals, and listen to see if you can hear the 'clunk' sound. Universal joints are the cross shaped items with round caps at either end just before the yoke and splined yoke. Check transmission cross-member mount for wear, or see if it's torn or any mounting bolts loose. A clunk sound in my experience, has either been one of these issues.
I had a similar problem and had to have the 4 wheel drive serviced. It need new grease. the grease i had was old and it was causing the gears not engage cleanly thus causing the grinding sound until they were realigned.
It is somewhat Normal Depending on how Loud the Clunking is. This is a Common Complaint on the Chevy 4x4's. I have verified this through the Dealerships here in Oklahoma and they all say the Same thing But, I am with you, They should go into 4x4 without that Clunk for as much as we pay for them.
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