transfer case actuator repair

[pieter4458]

Suddenly a few warning lights appeared (ABS, DSC and 4X4) on my dashboard and then the local technician diagnosed the problem as the Transfer Case Actuator. From various forums I have learned that the inside gear of the transfer case actuator unit can be replaced with an aftermarket part (plastic) or it can be temporary fixed by rotating the gear 180 degrees.

I have opened up my actuator today to discover that the gears are indeed stripped on the one side, causing the actuator to malfunction, but then I further noticed that there is also a second stripped area a few tooth away from the first one.

My questions are:

• why is it stripping only at one point of the gear?,
• in rotating the gear, should the 180 degrees be in the middle of the good area or at the beginning?,
• Does the motor unit of the actuator turns or only pulsates?
• Can the stripped gear cause a serious problem inside the Transfer case?

See attached picture of the stripped component.

[Clockwork]

kinda wish I looked into this before I paid $1500 to have ot replaced.

[JCL]

The gear turns to activate the clutches. Until the clutches wear significantly, they will always engage at the same point, and that is where the gear wears out.

The serious problem is that it won't activate, but it will still drive in rwd. It doesn't break the transfer case, just stops it functioning.