Many 4WD transfer cases use a chain to transfer torque to the front wheels, the pop that is heard
when the vehicle is placed into 4WD is caused by excess slack in the chain causing it to strike the
case before snapping back into position.
To test a transfer case for slack in the chain, place the vehicle in park and engage the parking brake.
With the case locked in park rotate the front wheel flange or output shaft back and forth and check
for play. There should be none or very little.
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