Transfer Case Will Not Shift

Cause	Correction
DEFINITION: While shifting from HI range to LO range, there is gear clashing, no HI range, or the transfer case will not shift from 4HI to 4HI Lock. Review the Symptoms - Transfer Case and perform the necessary inspections.
Shift cam and shaft assembly	Inspect for the following conditions: The shift cam for being worn The shift shaft torsion spring for being faulty Refer to Transfer Case Cleaning and Inspection . Replace the following components if found faulty: The shift cam The shift shaft torsion spring Refer to Transfer Case Disassemble and Transfer Case Assemble .
High/low range shift fork	Inspect the high low shift fork for the following conditions: Worn shift fork pads The roller on the shift fork for wear or damage Cracked or bent shift fork Refer to Transfer Case Cleaning and Inspection . Replace the following components if found faulty: The shift fork pads The shift fork Refer to Transfer Case Disassemble and Transfer Case Assemble .
Range sleeve	Inspect the range sleeve for the following conditions: Engagement teeth for burrs or damage Sliding freely on the mainshaft The range sleeve shift fork collar for excessive wear Refer to Transfer Case Cleaning and Inspection . Replace the range sleeve if it is faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
High/low planetary carrier	Inspect the high/low planetary engagement teeth for burrs or damage. Refer to Transfer Case Cleaning and Inspection . Replace the high/low planetary carrier if it is faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Mainshaft front support bearing	Inspect for the following conditions: Failed front mainshaft support bearing in the input gear Journal on the mainshaft for excessive wear or damage Refer to Transfer Case Cleaning and Inspection . Replace the bearing if it is faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the mainshaft if it is damaged. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Lockup shift collar assembly	Inspect the lockup shift collar assembly for the following conditions: Shift hub for binding Shift collar for damage Burred or damaged engagement teeth Refer to Transfer Case Cleaning and Inspection . Replace the shift collar assembly if it is faulty. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Drive sprocket	Inspect for the following conditions: Engagement teeth on the drive sprocket for burrs or damage Worn bushing in the drive sprocket Journal on the mainshaft for excessive wear or damage Refer to Transfer Case Cleaning and Inspection . Replace the drive gear if it is damaged. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the mainshaft if it is damaged. Refer to Transfer Case Disassemble and Transfer Case Assemble .