is it possible that the encoder motor doesnt shift my transfer case into 4hi or 4lo all the way and thats why its popping out also for my next test im going to pull encodermotor is there a shaft to grab and turn manualy just to see if it stay in 4hi

 

never saw an encoder motor 'pop' it out of 4wd but...I haven't seen it all yet. To your second question..once the encoder motor is pulled it will reveal a shaft with a slot in it that you can turn it-with say a prybar and manually put it in 4wd. Jerry

 

im not saying it pops it out im just thinking maybe its not putting it in all the way is there a clutch or something in there or on drive shaft

 

do you have the auto set-up? Meaning the 4x4 touchpad w/the auto function? I konda doubt it. If not, in 2wd your slipshaft should be free. Take off the encoder motor, revealing the shaft and turn it with, say, a prybar of sorts. The 1st click( position) should be 4 hi. Try it and see if it slips out-if that is what you're after. JP PS by doing this the formally free slip shaft should now be locked in.