Transfer case not shifting?

NEIL LONG

MEMBER
2003 CHEVROLET TRAILBLAZER
4.2L
6 CYL
4WD
AUTOMATIC
200,000 MILES

The problem is that when I use the switch on the dash to change from four wheel drive to two wheel drive it will not shift back into two wheel drive. I have tried changing the shift actuator on the transfer case and then it does not want to line up to put the bolts back in. Is something possibly wrong with the transfer case? All help would be appreciated. I have even changed the switch on the dash.

Wednesday, September 19th, 2018 AT 8:56 AM

3 Replies

KEN L

MASTER CERTIFIED MECHANIC
50,321 POSTS

To reinstall the encoder you must have the car in neutral and you must be able to turn the rear or front wheels. This will allow the transfer case to shift so you can get the encoder installed. Here are diagrams below to help you see how it works. Check out the diagrams (below). Please let us know what happens.

Cheers, Ken

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Friday, September 21st, 2018 AT 10:43 AM

NEIL LONG

MEMBER
2 POSTS

Ken, I had all four wheels off of the ground before when I tried to reinstall encoder motor. I tried turning the tires and and it still did not help. I even tried moving the splined, shaft to manually shift it to a position that would align with the encoder. Yesterday when I tried to drive it, it was making a growling and popping noise. Today I removed the front drive shaft just to see if the noise went away. There is no noise what soever with the drive shaft removed, but I know that it is just rear wheel drive now. Do you have any other suggestions? I think something may be wrong with the transfer case.

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Friday, September 21st, 2018 AT 5:31 PM

KEN L

MASTER CERTIFIED MECHANIC
50,321 POSTS

Yep, it sounds like the clutch pack is bad or you have a bearing out. Lets remove the transfer case and disassemble it to find out what is wrong it will be fun. Here are all the diagrams showing how to take it apart and instruction and what to look for as well.

You will need to use a press on parts of it this video will show you how to use a press.

https://youtu.be/g_hj1hRSNgg

Check out the diagrams (below) that show how to rebuilt the transfer case. Please let us know what happens.

Cheers, Ken

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