The front output shaft of the Borg Warner and LT230 Transfer Cases are prone to give trouble after years of hard use. Usually, the problem is worn bearings. The symptoms are a “clunk” from directly under the driver seat, especially when going from drive to overrun and back. Replacing the bearing is not too difficult a task and will be outlined here.
Note, this information is taken directly from the Shop Manual: (click below of each image for details)
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