I've tried changing the encoder motor with no luck .. Is there a way to manually engage 4x4 on these transfer cases with the clutch pack inside like send power to it and lock up the clutch and the lock in the front diff or is it more complicated than that ?

 

I'm sure you can take the encoder motor off, unplug the TCCM, and put the t-case in full 4WD with a wrench on the shaft. Also I'm sure you can bypass the vacuum switch for the front axle. That will get you 4WD (100% of the time) not Auto.

Will it be convenient to go back to 2WD - no. Will your 4WD light be on - yes. Will it be rinky dink - certainly!!

And all these electronics are called progress!! Instead of a lever and turning the locks on the front hubs, now we have a selector switch, a dedicated processor, a stepper motor, a PCM, an electronically driven vacuum switch, and a vacuum servo that operates a sliding sleeve for the right front axle. All so you don't have to get out in the snow to lock in the front hubs or even decide when to use the 4WD (Auto mode). The fancy new term for it in the new sport utilities is "Intuitive 4WD" - listen to the commercials! Like they have something new......

If you previously blew any fuses, most likely the encoder motor shorted out and ended up blowing the TCCM (current for the encoder motor goes through it). What happened to me. Definitely took both parts to fix mine.

Seems like I remember something about your 4WD issues from before (I could be wrong). If you asked anything here before about this problem you should not have started a new thread - best to keep everything together so we can see what has been said in the past. We simply can't remember it all.

Have you inspected the connectors on the TCCM for corrosion? Also you can check the function of the switch and wiring using a multimeter at the TCCM connector. Maybe this will help https://blazerforum.com/forum/tech-a...rmation-41198/

Good luck and best wishes for a successful repair.