4WD issues Solved!

[mzootie]

I have been troubleshooting for some time my 4WD issues. So I went through the progression of the grounds cleaning first. Then instead of replacing the Transfer case motor i decided to go after the position sensor within, much cheaper of course. I got the AC DELCO part on Amazon for $35. So when i disassembled the motor i noticed that the gears were previously matched marked but low and behold the factory match marks were not lined up. I went and installed the new sensor on the gear, and reassembled not where i found it but to the factory marks. There is a notch on the gear and one on the housing. So yes the smoking gun! I reassembled everything and my intermittent service 4WD and the selector switch with the random lights coming and going were gone! That's great unfortunately it still would not shift into 4WD. So next step was the front diff actuator. I removed it and gave it power but it didn't budge. So I checked the voltage at the plug and got the 12 volts on the hot- brown wire, but got no resistance on the ground - the black wire. Should have read 000 on the ohm meter but only read 1 meaning no ground. I tapped into the ground with a vampire connector right close to the plug instead of chasing it all the way back. I ground down a spot on the frame and ran new wire to the frame and fastened it with a self tapping screw. Tried it again and Viola! the motor turns. Reassembled it all and it works perfect. So there were actually 2 issues and it did take some time and online research help with diagnosis but was able to solve both issues for $35.

 

[Weezul]

Does the transfer case leak fluid when pulling the transfer case motor?