A transfer case (21, 330) and a method of assembly can include an input shaft (15) and output shafts (14, 16), a mode clutch (30) for shifting between a two-wheel and four-wheel drive mode, a mode shift mechanism (56, 380, 480), a planetary gear assembly (20) for providing a different drive ratio between the input shaft (15) and the output shaft (14), a range shift mechanism (50, 360, 460), and a synchronizer (40, 340) for speed synchronization before shifting between a low-range drive mode and a high-range drive mode. A fixed ring gear (24) can be connected to the planetary gear assembly (20) during the high-range and low-range drive mode. The mode shift mechanism (56) and the range shift mechanism (50) can be electro-mechanically actuated by a reversible rotatable actuating gear (348, 448) interposed between an expandable clutch actuator (388, 488) and a rotatable barrel cam (359, 459).