Well, I spoke too soon in my recent post. Word to the wise: Test your shift motor every couple of months. Don't forget about it until it starts snowing. We are getting snow, and sure enough, mine isn't working anymore
. It was intermittent, so I thought I would shift in and out of 4WD to exercise it an maybe wipe the position sensor contacts clean. It cycled a couple of times and then stopped working:roll:. I don't even hear relays clicking in the computer. The fuse is OK. When I press the button on the shift computer the LED lights for about 40 seconds and then goes out. I don't remember what that means, but I think it did that when I last repaired the shifter.
I replaced the plastic bushing years ago with a piece of rubber fuel line, but I suspect that now the rubber has deteriorated. When I did the first repair, I made a diagram of how the position sensor contacts work, so I can do a continuity test.
Right now I have the shift motor on the bench and the shaft position looks a little off, from the 2WD arrow I marked when I first repaired it, so I think (hope) that the rubber stop is the problem. Unfortunately, I can't get the cover off to have a look inside. Those 3 security torx screws are stuck. Even after spraying with penetrating oil, I broke the torx bit, and I thought that the last time I fixed it I used zinc grease on the threads. I'll keep spraying the screws every day, until I can get a new torx bit (20T security bit), but I may have to do the unpleasant task of drilling out the 3 screws. I'm thinking of drilling out the pins in the center of the torx screws so that I can use a conventional torx driver, which may be stronger, but that, too would be a pain. I'm thinking maybe heating the casting around each screw with a soldering gun might break them loose.
Ideas and sympathy greatly appreciated. Man, I'm almost ready to convert to a manual transfer case!
Bwana Bob