Is there anyway i can take the 4x4 stuff out or unhook somethin to get the truck out of 4 wheel drive... Im just gonna drive it in 2 wheel drive for awhile.... Is there a cable i can tug on to get the 4x4 off its electric shift t case and the switch appears to have no power and i checked all the fuses... thanks

 

Have you tried disconnecting the battery for about 3 minutes?
I guess to change it manually you could take the encoder motor off and turn the selecter shaft in the transfer case with a wrench. Then you would have to try to move the slot in the encoder motor to align the slot with the shaft to put the motor back on.
This is not a fact....just a thought.

 

Even if you removed the front shaft, you would still have to get the front axle to unlock as it will remain engaged until the relay tells it to dis-engage.

try searching http://www.car-parts.comfor yards local to you that might have this part used. Might be your best bet over buying a new one.

 

Which range are you stuck in 4HI or 4LO. If 4LO then you have to get to 4HI if you can, if not then you have to change the encoder motor, it shifts the transfer case from HI to LO range. To disengage 4X4 then you have to get the vacuum diaphram under the battery box to pull the cable to disengage the 4HI and get it into 2HI. If the diaphram is broken you can disconnect it and pull on the cable manually with a pair of vise grips (have read this on ZR2.com before it was gobbled up by ZR2USA.com and closed to non ZR2 members) this is a trail fix. Sometimes the diaphram stops working after a deep water/mud crossing...

 

To disengage the front axles, all you need to do is remove and plug the vavuum hose from the actuator under the battery.
With the transfer case locked in 4wd, the transfer case switch will not vent, so vacuum keeps the axles engaged to the front diff. (pulling the cable actually engages the front axles)
You might have a faulty encoder motor but the problem could also be the TCCM or the switch or the wiring.

 

Actually I know from recent experience that you can move the encoder motor slot with a half inch ratchet, it fits right in.

 

diaphram and cable were all seized up.. got it freed... plugged the vacumm line goin into the diaphram i think its still in 4 hi tho ill try it tonight... anything else i could try

 

wheres this encoder motor at that u can turn it with a socket to get it out of 4 wheel drive? sorry this is my first 4x4 i don't know alot.... thanks for all the help

 

Here is a small pic of the front of the transfer case driver side output shaft:



[IMG]local://upfiles/1127/80ADBBE6B282492E9A9C3A578FB15793.gif[/IMG]

 

so is it a hard job getting the electric motor off and if i changed the drive setting will my front hubs still be locked in? im still stuck in 4 high i need some more help thanks