Ok so, I re tested all of the wiring that I could get to. Seems like I have found and fixed all of the broken wiring. I tested the lock out solenoid wiring with jumpers and it’s clicking appropriately. The encoder sounds different now as in, it is making sounds that tells me that it is actually turning like it is supposed to. And it doesn’t shut down anymore. It tries a mode, clicks and whirrs, the goes back to 4wd. Now the funny deal is that Auto 4wd works. It allows the rear wheels to slip then engages the front wheels. Drive it to work today like this. I’m thinking maybe it’s out of calibration? Thoughts?

 

There might be a calibration for it, but I am not sure the process. There may also be something broken that is stopping the t-case from finding 2wd. Can you find 2wd manually?

I don't have the FSM for a GMT800, but if there is a calibration process, I am sure its on google

 

Thank you yes I am sure that I could find it manually. I haven’t tried to find that mode specifically but I have ensured that I can move the transfer case manually. I may disconnect the battery for a day.

 

Well, I figured I owed you guys an update, I ran out of free time for a while to work on the transfer case issue until this past weekend. I put the fuse back in after almost 2 months of it being disconnected. Same issue. I could go from 4wd to Auto 4wd but nothing else worked. I manually jumped the locking solenoid again to no gain. I unbolted the encoder motor and tried again. No movement just a bunch of whining and clicking. So I dug out the old original encoder. Found the plug that I had cut off of it to test it and wired it back together. I then plugged it up to test it and presto! It turns!!!! reinstalled it on the transfer case and it shifts out of 4wd to 2wd! Went to 4Lo then back to 2wd and left it. Guess time will tell if I need to use 4wd in the future.