Transfer Case - High Shift Effort

File In Section: 04 - Driveline Axle

Bulletin No.: 00-04-21-002

Date: December, 2000

TECHNICAL

Subject:
High Transfer Case Shift Effort (Replace Synchronizer Hub/Sleeve Assembly, Synchronizer Blocking Ring and Shift Shaft)

Models:
1999-2000 Chevrolet Tracker with 4-Wheel Drive

Condition

Some customers may comment on a high transfer case shift effort when shifting from 2H to 4H with the vehicle in motion.

Cause

This condition may be caused by high friction and engagement load within the synchronizer.

Correction

Replace the synchronizer hub/sleeve assembly, synchronizer blocking ring and front drive shift shaft. Use the following service procedure and part numbers listed below.

Important:
Improvements have been made to the above components which should reduce shift effort. The synchronizer inserts and spring have been eliminated to reduce friction.

Service Procedure

1. Remove the transfer case assembly from the vehicle.

Refer to the Transfer Case sub-section of the Service Manual.

2. Remove the synchronizer hub/sleeve assembly, synchronizer blocking ring and front drive shift shaft.

Refer to the Transfer Case - Tracker sub-section of Driveline/Axle in the Unit Repair Manual. Perform steps 1-17, 31-34, 41, 46 and 52.

3. Install the new synchronizer hub/sleeve assembly, synchronizer blocking ring and front drive shift shaft.

Refer to the Transfer Case - Tracker sub-section of Driveline/Axle in the Unit Repair Manual. Perform steps 1, 2, 7, 14, 24-31 and 40-70.

4. Install the transfer case assembly into the vehicle. Refer to the Transfer Case sub-section of the Service Manual.





Parts Information

Parts are currently availabie from GMSPO.

Warranty Information





For vehicles repaired under warranty, use the table.