The way your transfer case works is that it takes power from the transmission and directs it to both ends of your car, or axles, through two separate drive shafts. You can locate it on the rear of the transmission where it gets its power from the engine. Once the power comes through the engine to the transmission, it goes through the transfer case to the front and rear wheels. If your transfer case fails you can repair it, or replace it with a new or rebuilt transfer case. When your transfer case begins to fail you may notice the following issues:
Hearing a noise that sounds like a gear popping out could indicate the need more lubrication or that a component is worn. It could also mean that your gears are worn or damaged, or that your chain is damaged, in a chain driven transfer case.
Gears Popping Out
If your gears keep popping out, it can mean that your gears are worn and can’t keep your truck in two or four wheel drive. This is usually an issue that comes on gradually but can indicate a serious problem.
After time your seals can break down and start to leak. If you don’t address a leaking seal it can lead to inadequate lubrication and serious internal damage.
Hard shifting may be caused by a shift linkage that is bent or worn. In some cases, the linkage simply needs lubrication. If the linkage is okay, the problem may be caused by bent or damaged shift forks inside the transfer case.
Transfer Case Shudder
A hard jerking motion that occurs while accelerating could be caused by fluid levels, loose transfer case fasteners, worn gears or bearings, or defective internal clutches. A shudder may also occur at low speeds on vehicles with a defective viscous coupling or clutch pack.