Hi,
The idea that you sometimes hear a grinding makes me think the actuator is trying to shift but isn't able to. Are you sure the new/used actuator is good?
Do me a favor. I need you to check if the actuator motor is getting 12v when you request it to shift.
If you look below, I highlighted the shift motor. Each of the wires highlighted can supply power to operate the motor based on request. See if either get power when you try shifting.
Also, by any chance have you checked the fluid in the transfer case to make sure it didn't get water in it and damage it?
Let me know what you find.
Joe
See pic below.
Image (Click to make bigger)
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Monday, April 10th, 2023 AT 9:01 PM