Purchased an 04 CDL locking transfer case that seems stuck. got it bolted up to my transmission and neither output shaft will turn, almost like it’s in park. Even when in neutral or shifting from R to D it will not turn. I have switched from high to low range with same results and cdl locked and unlocked. If I leave the high/low in neutral it turns. I removed the inspection cover plate and the main gears seem fine. The gears will rotate approx 1” of travel but stops dead in either direction. I don’t have any driveshafts hooked up. I’m hoping it is something simple that I am overlooking. Any ideas? I have contacted the seller but am hoping this one is fine and I don’t have to remove from the truck again.

 

Maybe it’s seized.

 

how are you attempting to turn the shafts?

 

Tried by hand and unable to turn it. Started engine and tried between R and D several times with same result. Shaft coupler turns each way maybe 1/8 revolution and stops. I did not apply throttle.

 

So you have dropped the bottom access cover, the input shaft and intermediate shaft will turn as well as the main output gears, but the output shaft will not. Unlock the front diff and see if the front output shaft will turn. If it does, you may want to drop the parking brake to make sure it is not hte problem. If it still does not turn you have a seized rear output shaft. You should download the Rave manual and review the transfer case rebuild section.

 

Problem solved. 3 different sized bolts attach the xfer case to the transmission. They don’t vary by more than 1/4” but I had the longer ones in the two transmission to xfer case holes. This was protruding into the xfer case and binding against the gear. Thanks to the seller for suggesting to check!