Transfer Case Jumps Out of Gear

WARNING: This page is about a different car, the 2010 GMC Sierra, 2010 GMC Cab & Chassis Sierra, 2010 Chevrolet Silverado, and 2010 Chevrolet Cab & Chassis Silverado. 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.
Shift linkage worn	Inspect the shift linkage for correct adjustment or for being worn. Replace the faulty component. Refer to Transfer Case Control Lever Replacement and Transfer Case Control Rod Replacement .
High/low shift fork pads	Inspect the high/low shift fork pads for wear. Refer to High/Low Shift Components Cleaning and Inspection . Replace the fork pads if worn. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Faulty high/low shift fork	Inspect the high/low shift fork for being damaged. Refer to High/Low Shift Components Cleaning and Inspection . Replace the shift fork if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Faulty high speed teeth on the high/low clutch	Inspect for the following conditions: The input shaft high speed engagement teeth for wear or damage The engagement teeth on the high/low clutch for wear or damage Refer to Front Output Shaft and Input Shaft Cleaning and Inspection and High/Low Shift Components Cleaning and Inspection . Replace the high/low clutch if the teeth are faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the input shaft if the engagement teeth are faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Faulty control actuator shaft	Inspect the control actuator shaft for wear. Refer to High/Low Shift Components Cleaning and Inspection . Replace the control actuator shaft if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
High/low planetary carrier assembly	Inspect the high/low planetary carrier for the following conditions: Low speed engagement teeth worn or damaged Cracked carrier housing Planetary gear needle bearings worn Planetary gears broken or damaged teeth Planetary gears seized or binding Refer to High/Low Planetary Carrier Cleaning and Inspection . Replace the high/low planetary carrier if any of the above conditions exist. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Front output shaft drive sprocket	Inspect the drive sprocket for worn engagement teeth. Refer to Drive Chain, Drive Sprocket, and Driven Sprocket Cleaning and Inspection . Replace the drive sprocket if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
2/4 wheel drive synchronizer sleeve	Inspect the synchronizer sleeve for worn engagement teeth. Refer to Two/Four Wheel Drive Shift Components Cleaning and Inspection . Replace the synchronizer sleeve if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .