Transfer Case Jumps Out of Gear

WARNING: This page is about a different car, the 2005 GMC Yukon XL, 2005 GMC Yukon, 2005 Chevrolet Tahoe, 2005 Chevrolet Suburban, and 2005 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

Cause	Correction
DEFINITION: Loss of the transfer case drive torque during deceleration, acceleration or under load. Review the Symptoms - Transfer Case and perform the necessary inspections.
High/low shift fork pads	Inspect the shift fork pads for wear. Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the fork pads or other damaged components. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
Faulty high/low range fork	Inspect the high/low range fork for damage or wear. Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the high/low range fork if faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
Actuator lever worn	Inspect for excessive wear on the actuator lever - for not allowing full shift fork travel. Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the faulty actuator lever. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
Faulty high speed teeth on range sleeve	Inspect for the following conditions: The input gear high speed engagement teeth for wear or damage The engagement teeth on the range sleeve for wear or damage Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the range sleeve if the teeth are faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the input gear if the engagement teeth are faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
High/low planetary carrier	Inspect for the following conditions of the high/low planetary carrier: Low speed engagement teeth worn or damaged Cracked carrier housing Pinion gear bushings worn or out of position Pinion gears broken or damaged teeth Pinion gears seized Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the high/low planetary carrier if any of the above conditions are found. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
Input shaft pilot bearing	Inspect the bearing in the input gear and the rear output shaft journal for excessive wear. Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the bearing and the rear output shaft if faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
Input gear	Inspect the input gear for broken or damaged teeth. Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the input gear if faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.