Clunk on startup when in 4Hi - 25 Tacoma Sport

[TerryAlberta]

Notice a clunk from transfer case every time I start my Tacoma when it’s already in 4Hi. I assume this is engaging the 4wd but I’ve never heard this from my other 4x4’s - is this normal? This only occurs when I park in 4hi, shut it off and it then makes the noise / clink everytime I start it. I can also feel it and it will even move the truck slightly if parked on a flat surface.

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[TacoFreak]

No, that is not normal and I suggest that you take your truck to the dealer if you can replicate this.

 

[LincolnSixAlpha]

Terry, honestly I feel that the 4by system on this thing is a bit clunky in my opinion. Now I can only compare it to my last vehicle, 2021 Silverado, which had the clutch pack in the transfer case, so obviously throwing that into 4x the clutches absorbed all of the driveline lash and whatnot.

I'm not in 4x much, but I do but it in from time to time, when driving in a straight line for distances. I've found that exercising the system, components mesh in more, break in, and whatnot.

I live in phoenix, so not much need for 4x, save for off-roading. Dont do it much with this truck. I'm guessing yours is very new, break-it in, and take it from there. Personally I wouldn't worry about it, but those are my observations.

If your truck is new, keep in mind all of that garbage under there does need to break in and in particular the front diff gears need to get worked in together.

I will point out that mine has settled down with the clunkyness, over time and occasional usage. I'm just over 26K miles.

 

[TerryAlberta]

No, that is not normal and I suggest that you take your truck to the dealer if you can replicate this.

Ya it’s odd, I’ve never heard something like this - got it booked in.

 

[GPTaco]

Mine does the same, im in 4x4 a lot this time of year. Dealer checked once last winter but difficult to replicate so im going to revisit this issue in the new year when I book in my recall fix on the brake hoses and a couple other outstanding issues.
Maybe it's our lovely -40c Alberta winters playing havoc...not sure.

 

[TerryAlberta]

Terry, honestly I feel that the 4by system on this thing is a bit clunky in my opinion. Now I can only compare it to my last vehicle, 2021 Silverado, which had the clutch pack in the transfer case, so obviously throwing that into 4x the clutches absorbed all of the driveline lash and whatnot.

I'm not in 4x much, but I do but it in from time to time, when driving in a straight line for distances. I've found that exercising the system, components mesh in more, break in, and whatnot.

I live in phoenix, so not much need for 4x, save for off-roading. Dont do it much with this truck. I'm guessing yours is very new, break-it in, and take it from there. Personally I wouldn't worry about it, but those are my observations.

If your truck is new, keep in mind all of that garbage under there does need to break in and in particular the front diff gears need to get worked in together.

I will point out that mine has settled down with the clunkyness, over time and occasional usage. I'm just over 26K miles.

I’ve got just over 15 km on it and it seems to function ok but I don’t understand why it would engage everytime the ignition starts. I don’t usually leave it in 4hi but the roads are straight ice right now so leave it in 4hi in t

Mine does the same, im in 4x4 a lot this time of year. Dealer checked once last winter but difficult to replicate so im going to revisit this issue in the new year when I book in my recall fix on the brake hoses and a couple other outstanding issues.
Maybe it's our lovely -40c Alberta winters playing havoc...not sure.

The weather doesn’t help for sure. Mine does it everytime I start the truck, even in the garage - no problem replicating. Booked in for next week, will let you know what they say. Thanks

 

[907Yota]

I have been driving Toyota 4WD trucks (including 4Runner) since 1985 and my 2025. Tacoma is by far the worst when it comes to 4WD. It binds, it clunks, and has made some disturbing bang noises.

I was told by the service department these are all “normal” to use his explanation. I only have 3200 miles on the truck so far. I hope it doesn’t grenade on me.

 

[The Dude]

If it helps, my ‘25 doesn’t clunk on startup in the garage in 4HI in -20*C. Take that information as you will.

 

[TerryAlberta]

If it helps, my ‘25 doesn’t clunk on startup in the garage in 4HI in -20*C. Take that information as you will.

Thanks - that does help, the shop can’t tell me it’s normal.

 

[Yotota]

Everyone needs to state whether their truck is hybrid or regular engine on these type of discussions. Startup sequence and driving behavior is very different between the two trucks.

If the truck is stationary and making that clunk, it might be the transfer case actuator moving. I don't recall hearing that happen on my regular engine TRD OR when I park it in 4hi, then start it again.

It might also be a COOOOOLD weather thing due to the transfer case oil thickening. You'll need to test this with another truck (same as yours, either hybrid or not) in similar weather.

Test idea:

Next time you park, put the truck back into 2hi before you shut it off and make sure the 4hi light is out. Then on the next startup, as soon as the engine is running, put it in 4hi. I bet it's the same clunk.

 

[TerryAlberta]

Everyone needs to state whether their truck is hybrid or regular engine on these type of discussions. Startup sequence and driving behavior is very different between the two trucks.

If the truck is stationary and making that clunk, it might be the transfer case actuator moving. I don't recall hearing that happen on my regular engine TRD OR when I park it in 4hi, then start it again.

It might also be a COOOOOLD weather thing due to the transfer case oil thickening. You'll need to test this with another truck (same as yours, either hybrid or not) in similar weather.

Test idea:

Next time you park, put the truck back into 2hi before you shut it off and make sure the 4hi light is out. Then on the next startup, as soon as the engine is running, put it in 4hi. I bet it's the same clunk.

Good idea I’ll give that a try - it’s not a hybrid. I have a buddy with the same truck and he hasn’t noticed it. It’s stored in heated garage and does same thing warm or cold. Thanks

 

[Yotota]

Good idea I’ll give that a try - it’s not a hybrid. I have a buddy with the same truck and he hasn’t noticed it. It’s stored in heated garage and does same thing warm or cold. Thanks

Interesting on the heated garage aspect.

Do you have to turn to get into the garage? Or are you driving straight in before and into the garage?

With a turn, and in 4wd, it could be a drivetrain binding situation.

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