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Transfer Case - BW44-45

WARNING: This page is about a different car, the 2013 RAM 1500. However, it is still accessible from the selected car via links, so may be relevant.
DIAGNOSIS CHART

Condition Possible Cause Correction
Transfer case difficult to shift or will not shift into desired range. 1) Transfer case electronically controlled shift system malfunction. 1) Check for Transfer Case DTCs. Refer to appropriate Electrical Diagnostic article. Depending on vehicle configuration (FCM, FDCM, or DTCM), perform the appropriate diagnostic procedure and verification test.
2) If vehicle was operated for an extended period in 4HI mode on dry surface, driveline torque load may cause difficulty. 2) Drive the vehicle in a straight line and momentarily release the accelerator. The transfer case can then be shifted to the desired mode.
3) Insufficient or incorrect lubricant. 3) Drain and refill transfer case with the correct quantity of fluid. Refer to CAPACITIES AND RECOMMENDED FLUIDS, DESCRIPTION .
4) Internal transfer case components binding, worn, or damaged. 4) Repair or replace components as necessary.
Transfer case noisy in all drive modes. 1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with the correct quantity of fluid. Refer to CAPACITIES AND RECOMMENDED FLUIDS, DESCRIPTION .
2) Internal transfer case components binding, worn, or damaged. 2) Repair or replace components as necessary.
Transfer case noisy while in, or jumps out of, 4LO mode. 1) Transfer case not completely engaged in 4LO position. 1) While rolling 2-3 MPH and the transmission in NEUTRAL, shift transfer case to the 2WD or 4HI position, and then back into the 4LO position.
2) Range fork damaged, inserts worn, or fork is binding on the shift rail. 2) Repair or replace components as necessary.
3) Low range gear worn or damaged. 3) Repair or replace components as necessary.
Lubricant leaking from transfer case seals or vent. 1) Transfer case overfilled. 1) Drain lubricant to the correct level.
2) Transfer case vent closed or restricted. 2) Clean or replace vent as necessary.
3) Transfer case seals damaged or installed incorrectly. 3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4HI mode on dry surfaces, 1) Operate vehicle in 2WD mode on dry surfaces.