I've got a major problem with my transfer case...the shifter seems to be seized. Over the last few years I have'nt used the truck very much and noticed that it began to need 2 hands to pull it into 4 hi.....I just figured it was from lack of use. This winter I went to put it into 4 hi and the shifter would not move period, naturally I grabbed the steering wheel and pushed that lever till it snapped...today I replaced the entire shifter mechanism for $200 and reminded myself that flipping out costs money LOL. Does anyone have any input as to what to do about this aside from pulling the case ( I'm totally broke) and is this a common problem ? the tcase is full and I've never had any issues with it before.....I'm thinking it might loosen up if I begin to drive it on a regular basis again and get that fluid splashing up on the shifter forks etc. Any ideas ? Thanks............

 

You can pull the case, its free as long as you have tools. If you split the case then you'll need some more fluid and some rtv sealant.
anyways....I would start by checking the linkage under the truck, see if its corroded or something got stuck up there thats preventing you from shifting it. I don't think your problem is that common, I rarely use 4x4 and it always shifts with ease. What type of tranny do you have?

FYI: Pulling the case isn't hard, it can be done in less than an hour, its a little over 100 lbs. so it kinda sucks putting it back in the truck, but it can be done. I've pulled my xfer case several times with no issues and I always man-handle it back into place.

 

It's an NV 241 HD, the linkage is fine, (just replaced shifter) its been getting progressively harder to shift (stiff) over time, the thing that has changed is the amount I drive the truck, I used to drive 100 mi. to work each day down to 2-3 times per month if at all. I find it hard to believe it's having this problem, I mean it should'nt. (I have a '78 chevy 3/4 ton that still shifts like butter since new) This problem is driving me crazy, I really need my 4wd in the winter !

 

keep us posted as to what you find as I have the same problem sort of my shift lever moves into 4 wh but when moves into N or 4wl it doesn't engage, when in those positions it is extremely hard for even me to move back into 2wh, I have a post about this also from a few weeks ago. not quite you problem but i believe they are related, good luck

 

Not unsual for unused shift shaft to seize in case. You might try tapping with small hammer to loosen. Have some one puting light pressure back and forth on lever and tap in lighty and then try pry out. Gently remember. Try working some penatrating oil also.
Moisture migrates into unused shaft and slowly seizes the shaft.

 

It's also possible the 4wd switch on the top of the transfer case is getting sticky or seized and preventing the sector from moving inside the case. I would try shifting it with the switch removed before I went any farther.