Transfer case with range and mode actuator having cam follower mechanism to overcome blocked shift events and sensor configuration permitting detection of fork positions

A transfer case comprising:

• a housing;
• and
• an actuator with a motor and cam assembly, a fork shaft, a first fork, a second fork, a sensor target and a sensor, the motor and cam assembly being coupled to the housing and having a motor, an intermediate shaft, a cam structure and a torsion spring, the motor driving the intermediate shaft about a cam axis, the cam structure being received coaxially over the intermediate shaft, the torsion spring being disposed in a torque transmission path between the intermediate shaft and the cam structure, the cam structure defining first and second cam tracks, the fork shaft being coupled to the housing and extending along a fork shaft axis that is parallel to the cam axis, the first fork being received in the housing and having a first mount, a first fork member and a first cam follower, the first mount being received on the fork shaft for sliding movement along the fork shaft axis, the first fork member extending from the first mount and having a pair of first fork tines that are disposed about an actuation axis that is parallel to the fork shaft axis, the first cam follower being coupled to the first mount and being received into the first cam track such that rotation of the cam structure about the cam axis between a first rotary cam position, a second rotary cam position and a third rotary cam position causes corresponding translation of the first fork along the actuation axis between a first position, a second position and a third position, respectively, the second fork being received in the housing and having a second mount, a second fork member and a second cam follower, the second mount being received on the fork shaft for sliding movement along the fork shaft axis, the second fork member extending from the second mount and having a pair of second fork tines that are disposed about the actuation axis, the second cam follower being coupled to the first mount and being received into the second cam track such that rotation of the cam structure about the cam axis between a fourth rotary cam position and a fifth rotary cam position causes corresponding translation of the second fork along the actuation axis between a third position and a fourth position, respectively, the sensor target being coupled to the cam structure for rotation therewith, the sensor target defining a target profile with a plurality of different rotary plateaus, the sensor sensing the target profile and responsively generating a sensor signal.