This might help: http://www.rsgear.com/articles/2006_02.pdf

 

Just a quick question to make sure I know how this operates.

Does the switch in the dash send a signal to the TCCM, which sends a signal to the encoder motor, which engages and sends the vacuum from the transfer case switch to the actuator under the battery, which pulls a cable that locks in my 4x4?

Am I in the right ballpark here?

 

Perfect! When the encoder performs a "mode shift", (2HI to 4HI) linkage inside the case depresses the vacuum switch and sends vacuum to the actuator. During a "range shift" (4HI to 4LO) the vacuum switch remains depressed. The actuator pulls a cable that operates a shift fork in the right front axle tube. The fork moves a clutch, (synchronizer) that engages the inner axle with the outer axle and the front differential is live.

 

I had the exact same problem after replacing and looking over everything it ended up being my encoder motor. Try smacking the cylinder part of the encoder motor with a hammer then try and ingauge it. mine was seized

 

Yeah that's whats all roads are leading to, ill try and get one next week guys thanks for the help and ill let you guys know what happens.

As for hitting it with a hammer that's one of the first things I did lol