If you disconnect the encoder motor from the tbox, can u switch the tbox manually with a wrench into all positions and have drive?

 

I haven't tried it with the new encoder. The last time I disconnected the tccm, it worked in all positions, for a few tries

 

Due to the fact that it gave me lots of trouble changing the encoder motor, I don't really want to pull it back off and try shifting it manually. If it works correctly a few times after disconnecting the tccm, would it be safe to assume that replacing the tccm would fix it?

 

There are contact points in the encoder motors, if the required contacts are not seen when the encoder motor shifts to 4HI..systems goes to default and backto the previous gear change.

It could also be a TCCM..something is either blocking the gear change or the TCCM is just not seeing the required gear change position in the requested position when the selector shaft is moved..either TCCM, or encoder motor, or wiring, or tbox..hehe thats really the whole system of parts to make the gear change..but if you can delete the thoughts of a possible mechanical fault, your half was there

But even with the old encoder off, did you try to move the tbox though the gears and see if there is drive in those positions?

 

I didn't try it when I changed the encoder. I do know that it does work in all positions, I can get 4hi to work occasionally. That is one reason that I am leaning towards replacing the tccm. The new encoder solved one issue, just not all of them. I would like to find a wiring diagram with correct voltage readings, so that I can the entire system properly

 

I am happy to say that I do believe my 4wd is fixed. I disconnected the tccm for about 30 to 45 minutes and did the ignition cycle 5 times. It now works in all positions. I cycled it through all 3 positions multiple times while driving up and down the driveway for about 5 minutes. Ran a dtc and there are no codes. Just need to find a field or gravel lot to give it a thorough test.

Thanks to everyone for all you help.
This is an awesome group.
I can only hope that my trails with my 4wd problems will help someone else.