Transfer Case Will Not Shift

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: While shifting from HI range to LO range, there is gear clashing or the gear range cannot be selected. Review the Symptoms - Transfer Case and perform the necessary inspections.
Actuator lever	Inspect the actuator lever at the shift fork cam for being worn. Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the actuator lever if found faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
High/low range shift fork	Inspect the high/low shift fork for the following conditions: Worn shift fork pads The roller on the shift fork for wear or damage Cracked or bent shift fork Shift fork springs and brackets for damage Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the following components if found faulty: Shift fork pads Shift fork Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
Range sleeve	Inspect the range sleeve for the following conditions: Engagement teeth for burrs or damage Sliding freely on the rear output shaft The range sleeve shift fork collar for excessive wear Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the range sleeve if faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
High/low planetary carrier	Inspect the engagement teeth for burrs or damage. Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the high/low planetary if faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.
Front input shaft pilot bearing	Inspect for the following conditions: Failed front input shaft pilot bearing Journal on the rear output shaft for excessive wear or damage Refer to CLEANING AND INSPECTION TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the bearing if faulty. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8. Replace the rear output shaft if damaged. Refer to TRANSFER CASE DISASSEMBLE and TRANSFER CASE ASSEMBLE in TRANSFER CASE - OVERHAUL - NVG 246-NP8.