I have not checked to see if it shifts ok with motor removed.but I will a.s.a.p.

 

Last night I remembered that I tried in neutral to go from 4low to 4hi, wich it did. I could tell it wasn't in 4low any more just by putting it in drive. Just like you said lesmyer it was stuck in 4hi. This morning I put it in nutrual and attempted a 4low shift, it worked, I then attempted a 4low to 2hi shift. The tranfer case shifted to 2hi. Front drive shaft I can turn it now. Next step is to check voltage again at stepper motor connector 4 chanel outputs from tccm. This has become a quest for me now lol! Thank you very much lesmyer for your help!

 

Haha!! I've narrowed it down to the TCCM or the Encoder Motor or the Transfer case!! Not sure if i have helped or confused things! Good luck!!

 

Lesmyer i agree with your synopsis, I will focus on tccm, encoder then damage or wear in tc. Will post my finding as I go. Maybe it will help others. Thanks a bunch to everyone!!!

 

this was actually a joke, since I haven't helped to narrow things down at all. I would first out the new tccm in, clear the codes, and then check voltages. If voltages are ok but still no work, try another new encoder. Pretty much all you can do without a capable scanner. Best wishes

 

Oops I didn't realize it was a joke, your input helped me think outside my usual box. Sometimes I have brain parts as I get older! 😆 I put the new tccm in, same condition. Next I will test all 4 chanells for 5v reference, then move on to stepper motor and tc. Im about read to cut a hole in my floor and shift it with a wrench. Then run actuator to engine vacuum! Lol

 

Farts, see another one 😆

 

I hope it's OK to add my thoughts. I have had a similar problem where the vehicle would not shift into 4HI. In my case the problem was the transfer case encoder motor.

Since your encoder motor is new, to me it seems unlikely (but possible) that it is faulty. I have to wonder if turning the switch in the motor to allow it to slip over the shaft is the problem? If I recall the service manual says not to do this. I can imagine if the switch really is out of position, it would not send the correct signal.

If I understand correctly, a person is supposed to turn the transfer case shaft to get it to line up.

Alternatively, a person can turn the transfer case switch by connecting it with leads to a battery. The two shortest pins in the electrical connector operate the motor. Reverse the leads to turn the motor in the opposite direction. Realize that if you do this, it will require many many attempts and alot of patience to get the switch to land in the correct position.

I suspect it would be easiest to set the transfer case shaft to the middle position, and then mark the encoder motor at the middle position to get it to line up. Although I have not tried it.

As an aside, my 4wd worked through winter and spring, but come fall it had failed! I found that removing the encoder motor and working it back and forth with battery leads "loosens it up" and allows it to work for another season. (This summer I have been putting it into 4wd at least once a week to prevent the encoder motor from becoming sluggish.)

 

I welcome all perspectives, that's how we figure things out and save good money. Its all Good. I have electrical gremlins hiding on me lol. That I will tackle first. I did postion the tc shaft in the proper position for stepper motor installation. But the bolts holes and threads didn't line up. They were as much as 3/4 of a hole off. I have to tweak the shaft to get the threads start. Indicating mechanical wear as you were saying. I think I'm just gonna make a hole in the floor to shift it with a wrench. Then make a cover. Run vacuum to the actuator with a valve I can just open and be done with it. I only really use 4hi for the power losses to get fuel or the dump.

 

When time allows, I'm gonna check the 4 channels at stepper motor connector for 5 volts then go from there. Troubleshooting says I should have 5v in 2 hi with key on. Then look into motor.