Currently have my transfer case pulled, looking at the rear output shaft of the trans. Shaft has about 1/8th inch vertical play accompanied by a clunking sound. Bad output shaft bushing? Or is play acceptable here since it connects to the transfer case and is held solid by that?

 

I don't believe there should be any "vertical" play here.

End play spec on the output shaft is .0106"-.0339"

Sounds like there is a worn bushing or bearing, but, I can't help you any more than that.

Here is a link to the AW4 transmission manual:

http://www.pirate4x4.com/tech/billav...AW4_manual.PDF

 

Hmm ok, I measured it at .012" radially, so I am within spec. Its just that slight knocking that has me concerned, as I am having vibration issues

 

Why do you say there is a slight knocking noise in the transmission? when is this knocking sound happening? did you pull the transfercase due to vibration ?

 

When, specifically, do you hear the clunk?

 

Maybe this thread needs merged or killed since you've asked the same question in the "Ask the question" thread.

 

Yeah sorry, I had posted there first but it's sometimes harder to get a reply in the ask a question thread, couldn't figure out how to delete it. It clunks when I push up on the output shaft. And yes I pulled it because of vibration I've been chasing for a while now

 

No worries, it's just easier to keep track of answer/progress in one thread.

Sounds like you're going to have to tear into the tranny or find a new one. There shouldn't be any clunking when you push on the shaft.

Let us know what you find out.

 

Yep looks like it..

Will do! Thanks for the advice