For those who do have this clunk, just search for "slip yoke" on this site. If you still aren't sure about how to go about fixing it, go buy a manual...it is a good investment. I can go through the procedure that I used on my 98 sport 4x4...
1. Pull truck into garage or level surface.
2. Block front tires.
3. Put truck in Neutral with e-brake ON.
4. Jack back end up to get wheels off ground and support with jack stands or what have you.
5. Use some paint, I used touch up paint, to mark the orientation of the drive shaft flange and the diff flange, do the same for the transfer case.
6. With a 12pt 12mm socket, remove the 4 bolts on the rear of the drive shaft. You might have to release the e-brake to turn the shaft to get at some bolts. Then put it back on so the shaft doesn't turn while you are removing the bolt.
7. You can then do the same for the front of the rear drive shaft. I didn't actually do this because the bolts on the front were really on there. Instead, I cut the one time use metal straps that hold on the rubber boot which is around the yoke. I then dropped the rear of the shaft and pulled the yoke apart. I looked inside the cup piece and saw shiny metal at the end, I then knew that was definately the reason for the clunk.
8. Take shaft to a bench and wipe yoke if grease looks dirty.
9. Clean inside of yoke cup and rubber boot if dirty. I just stuffed a rag in.
10. Load cup and rubber boot with a "****load" of grease. I used some high temp bearing grease, but any thick grease will work. I suggest using gloves. I went through 3 pairs.
11. Load male end of yoke with grease in grooves and on the end.
12. Stuff yoke together to push grease to the end. i had to push hard to get the air out because the grease acted as a seal.
13. Pull yoke apart again and repeat 10,11, and 12 to your disgression. Don't forget the rubber boot.
14. Orient your paint marks on the flanges. May have to turn shaft.
15. Put the 4 bolts back in.
16. Install some new hose clamps on to boot. I used a 2" and a 2.5". I think a 1.5" and a 2" would have been better so you don't have much strap left over. Stainless is a ***** to cut.
17. Clean up any excess grease.
18. Lower truck and take for a spin, NO MORE CLUNK!!!
Hope this helps.
