I have a 2002 Jimmy SLS 4 Door 4WD 4 button (NP8).

My 4 WD originally broke about 2 years ago drive shaft was done and the vac hose fell apart and the actuator cable failed. I replaced all of that and changed the t-case fluids and seemed to have an issue disengaging from 4 LO so I changed the shift motor. Afterwards a friend of mine tested the old original motor and couldn't really find any issue with it so we kept it. Occasionally afterwards I would still have the issue so I took the shift motor off and took it back under warranty and replaced it. This time when I went to install the shift motor I found the shifter on the transfer case seems to be slightly bounded and took a small amount of pressure to move it to 4 hi. Then for a few years it seem to work OK but once in a while it would take two or 3 tries to get it out of 4 LO.

I used 4 LO a few weeks ago and again everything seemed OK. Last night I decided to try it again and this time it wouldn't come out I probably tried it a few dozen times and still wouldn't come out of 4 LO. So I check the actuator and it seems good. Put it up on axle stands and I try it a few times and it finally comes out of 4 LO and I can shift between 4 Hi, Auto and 2 WD. For the moment I have decided not to try 4 LO.

My question what would be causing this I don't think it is the shift motor, is 4 LO shot on the T-case so I need a new one? If we remove the T-case can we open it and look for something causing the binding?

Thanks for anyone's help and suggestions