I have a 03 2500HD with a 4L80e and a NP263HD transfer case with the 3 button switch on the dash. My problem is that the case is stuck in 4lo and I can't get it to switch back into 2hi. My buddy at the chevy dealership checked the codes today and there were about 11 tranny codes in total. He cleared them out and were gonna see what comes back on Thursday. Is there anyway to manually put the case in 2hi? I'll update on Thursday with the codes.

 

Yes you can manally put it in 2hi if you take the encoder motor off of the side of t-case and use a crescent wrench to shift it. if its only to get you by you can leave the motor off till you find a fix. What does the button do when you try to shift it? Does it just flash or does the switch even light up. Most of the time i have had to work on the 4x4 system either the switch went bad or the encoder motor on transfer case.

 

Most of the time the red neutral light on the switch is on. If I turn the key to the on position and hold the 2hi button I can get it to flash and sometimes it will even light up. Yesterday I tried holding the 2hi button and the 2hi and 4lo buttons stayed on my whole drive home from work. If I take the motor off is there a hole there that would leak if I drive around like that until I can get a new motor?

 

No. the shaft has a seal around it.

 

awesome that will work. Do you know which position is 2hi? All the way forward or all the way towards the rear of the truck?

 

its gonna be two clicks away from 4LO.. not sure which direction.. first click should be N second should be 2HI, third click should be 4HI

 

Ok so I took the motor all apart tonight just to see what was goin on inside and it was full of water and the wiring harness was unplugged from the motor and encoder ring. I cleaned and dried everything out, put the case in 2hi, and got the gears in the motor lined up with the shaft soes I could put it back on. Now the motor is working but I didnt position the gears properly im guessing because with the 4hi button is on its actually in 4lo so when u press the 4lo button it puts the case in 4hi. When I press 2hi it just flashes and stays in the 4hi position which actually leaves the case in 4lo. Seems like the motor is 180degrees out. How do you postion the gears properly?

 

Im wondering if I take the motor off the case and hit the 2hi button and put the case back in 2hi if they will line up?

 

They should.

 

It did work. The 4wd system is now fully functioning and it didn't cost me a single dollar.