Transfer case having an actuator assembly with cam follower that is molded into a plastic actuator structure

A transfer case comprising:

• an actuator assembly having an actuator structure and a cam follower, the actuator structure being unitarily formed of a plastic material, the actuator structure defining a sleeve structure, a fork structure and a follower mount, the sleeve structure defining a shaft aperture that extends longitudinally along an actuation axis, the fork structure extending radially outwardly from the sleeve structure and defining a U-shaped fork member having a pair of tines that are disposed about an engagement axis that is parallel to and radially offset from the actuation axis, the follower mount extending radially outwardly from the sleeve structure, the cam follower being formed of metal and being partly encapsulated in the plastic material of the actuator structure, the cam follower extending from the follower mount along a follower axis;
• wherein the follower axis is parallel to the actuation axis, and wherein the follower axis is rotated about the actuation axis relative to the engagement axis;
• and
• wherein the cam follower has a follower contact surface that is defined by a spherical radius.