Transfer Case Jumps Out of Gear

WARNING: This page is about a different car, the 2007 GMC Sierra and 2007 Chevrolet 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.
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 High/Low Shift Fork Replacement .
High/low shift fork spring assembly	Inspect the high/low shift fork spring assembly for the following conditions: Worn high/low shift fork pin Worn cam Broken spring Refer to High/Low Shift Components Cleaning and Inspection . Replace the following components if found faulty: The high/low shift fork spring assembly The high/low shift fork pin Refer to High/Low Shift Fork Replacement .
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 .
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 .
Input shaft pilot bearing assembly	Inspect the bearing in the input shaft and the rear output shaft journal for excessive wear. Refer to Front Output Shaft and Input Shaft Cleaning and Inspection and Rear Output Shaft Cleaning and Inspection . Replace the bearing and the rear output shaft if faulty. Refer to Input Shaft Pilot Bearing Replacement (Heavy Duty and Super Heavy Duty) and Transfer Case Assemble .
Input shaft	Inspect the input shaft for broken or damaged teeth. Refer to Front Output Shaft and Input Shaft Cleaning and Inspection . Replace the input shaft if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .