Hello. I came across this thread while Googling my issue. Sounds like it falls under the OP's post. I took my truck in yesterday for this issue. I had been experiencing it off and on the about the last 2 months. To recap, I would hear, and feel, a clunk. Sometimes immediately after I started my truck, prior to putting it in gear. Most of the time I heard and felt the issue after starting the truck and either putting it in Drive or Reverse to drive away, depending on how I was parked. This issue has occurred both with, and without the parking brake engaged. I know this is sometimes to be expected when parking on a measurable incline, but this is normally not the case for me, usually parking on completely flat surfaces.
As of now, the service manager has told me the following:
"The issue you are experiencing is due to some internal issues within your transfer case. When using stethoscope the technician can gear clunking inside of transfer case and has noticed the fluid was uncommonly dark for the miles on the vehicle. This is generally caused by the transfer case having more heat than normal due to shortcomings. Our plan is to replace transfer case and fluid, and this should solve issue. I ordered the parts but have not seen them arrive yet. Best to drive it sensibly and to not use 4wd to be on safe side."
He basically said that the excess heat being generated is boiling the transfer case fluid and it's no longer protecting the vehicle.
I will update this again after the work is performed and give a list of the parts that were replaced, as well as circle back around here after a week or two to give an update on how the truck is performing, post-repair. I was told when I left the dealership that the parts will take about 5 business days to arrive and that the repair will take about 2 days. The earliest expected date after parts are ordered and installed is looking like the week of Monday, September 25th, 2023.
Thankfully this will fall under the drivetrain warranty. Otherwise it would cost several thousand dollars. I own a 2020 Rebel with 45K miles on it, so the bumper-to-bumper warranty has expired.
So, my advice to anyone experiencing this is to get to your preferred local dealer and have it looked at sooner, rather than later.