Because so many threads die without any resolution or updates, here's one.

I got the new encoder today and it's as stiff or stiffer than the one I took off. I have no doubt in my mind the encoder is not the issue. I'll start getting ahold of TCCM's and see if that fixes the issue.

 

Thanks for following up with your encoder observations. I suspected that you would find similar resistance. Hopefully you can just return the new encoder and not be out that $$.

I would think that the wiring/connections between the encoder & the TCCM would have to be good and that it would be something internal to the TCCM that affects the switching of the current flow when reversing the encoder that is at fault. Some back-probes with a multimeter or oscilloscope and a full-feature scantool would really help you narrow down the true cause, but short of having that equipment, swapping parts will eventually get to the source of the problem.

 

So after re-installing the encoder and the tccm, everything seems to be working fine in this snowstorm we are having. No noticeable sticking of the AWD system. I have 3 extra TCCMs on hand in case things start go wrong.

 

BJ did you install a new tccm? and reinstall the last new encoder motor? Thanks for the update.

 

Nope kept the same tccm and same encoder. I don't believe the problem is fixed, but for now I'm not gonna fix what isn't broken.

Perhaps unplugging and plugging in the TCCM allowed better wire contact? I actually opened it completely up to see if there were any obviously fried components or broken solder joints.