Transfer Case Jumps Out of Gear

WARNING: This page is about a different car, the 2007 Hummer H2. 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 detent cam worn	Inspect for excessive wear on the shift detent cam, not allowing full shift fork travel. Refer to Cleaning and Inspection . Replace the faulty shift detent cam. Refer to Transfer Case Disassemble and Transfer Case Assemble .
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 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 high/low planetary carrier assembly if the input gear engagement teeth are faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
High/low planetary carrier	Inspect the high/low planetary carrier for the following conditions: 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 .
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 it is faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Lockup shift assembly	Inspect the lockup shift assembly for the following conditions: Worn or damaged sleeve Lock up collar teeth worn or damaged Refer to Cleaning and Inspection . Replace the lockup shift assembly if it is faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Planetary differential	Inspect the planetary differential for the following conditions: 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 planetary differential if any of the above conditions are found. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Mainshaft front support bearing	Inspect the bearing in the input gear and the mainshaft journal for excessive wear. Refer to Cleaning and Inspection . Replace the bearing and the mainshaft if they are faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Sun gears	Inspect the sun gears for broken or damaged teeth. Refer to Cleaning and Inspection . Replace the sun gears if they are faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .