Transfer Case Jumps Out Of Gear

WARNING: This page is about a different car, the 2007 GMC Yukon XL, 2007 GMC Yukon, 2007 Chevrolet Tahoe, 2007 Chevrolet Suburban, and 2007 Chevrolet Avalanche. However, it is still accessible from the selected car via links, so may be relevant.

Transfer Case Jumps Out of Gear

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 . Replace the fork pads or other damaged components. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Faulty high/low range fork	Inspect the high/low range fork for damage or wear. Refer to Cleaning and Inspection . Replace the high/low range fork if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Actuator lever worn	Inspect for excessive wear on the actuator lever - for not allowing full shift fork travel. Refer to Cleaning and Inspection . Replace the faulty actuator lever. Refer to Transfer Case Disassemble and Transfer Case Assemble .
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 . Replace the range sleeve if the teeth are faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the input gear if the engagement teeth are faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
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 . Replace the high/low planetary carrier if any of the above conditions are found. Refer to Transfer Case Disassemble and Transfer Case Assemble .
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 . Replace the bearing and the rear output shaft if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Input gear	Inspect the input gear for broken or damaged teeth. Refer to Cleaning and Inspection . Replace the input gear if faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .