Is this normal??!!

On my 2002 Xterra when I shift into 4WD HI at any speed over 5mph, it's kind of difficult to shift the transfer case, and occasionally I get a pretty substantial clunk and twice now I've gotten loud grinding sounds. This only seems to happen on the FIRST shift into 4WD. After that first time, I can shift into and out of 4WD with no sound or noticeable jolt what so ever.

Is anyone else experiencing this?

clunk sometimes. grind no. you may have a problem with the hubs. I hope you are not doing this on pavemant.

The clunk is the hubs engaging. If you shift too slowly it will grind. You have to manhandle it when you shift. The reason it only clunks the first time is because after that the hubs are already engaged until you back up in 2WD.

Originally posted by ChuckH
The clunk is the hubs engaging. If you shift too slowly it will grind. You have to manhandle it when you shift. The reason it only clunks the first time is because after that the hubs are already engaged until you back up in 2WD.

Thanks for the explanation. That's exactly how mine's acting. I guess I just need to pull harder on the shifter to avoid the grinding.

Many thanks.

Yeah, most X owners get a little weirded out when they gingerly shift and get that noise. I agree - I dont think you have a serious issue - just hubs engaging. Make sure you back up in 2WD when you are done wheeling though - it helps!

The same thing is happening to mine from "transfer case" neutral to 4hi. All other correct procedures are being used. I would assume that the hubs are already locked at this point. Any thoughts?

Although the Xterra is a shift-on-the-fly system, I am old school. I can't seem to get myself out of the habit of stopping the vehicle prior to putting it in 4WD. Now that I have manual hubs it is a necessity anyway. It probably is a good habit to get into even though it isn't really necessary. When I am on a ski trip and I think that 4WD may be required, I will lock out the hubs and usually try to make the shift at redlights while stopped. But that occasion is VERY rare (being from Florida). I have never heard my transfer case grind, unlike the Jeep I used to have. Even going from high to low. You might want to have the dealership verify that it is ok and it would be a good idea to take someone for a ride around the parking lot so they can see what you are doing when it occurs. That will verify whether you are doing anything wrong and insure the dealer rep verifies your complaint if not. As New Car Service Manager at a major car dealer, I can tell you from experience that is important. It is supposed to be a synchronized transfer case in high range and that grinding would concern me enough to have it looked at.

If you don't shift through neutral quickly, things will get out of sync and grind. You do not pause in neutral, just pass right through it rapidly and it shouldn't grind. If it does grind, shut the engine down, put it in the desired position, and you'll be OK.