Not fully engaging into 4WD

Hi,

Thanks for the question. These are electronically controlled and it sounds like you replaced all the applicable parts. The switch, the shift motor, and then the transfer case itself. When you move the switch it commands the motor to shift the transfer case so if it is moving but not fully engaging, then I would assume that the switch and wiring are okay. These leaves the mechanical components, the motor and transfer case itself.

Where did you get the transfer case? Is it new or used out of another vehicle? I know you said you bought a "new" one but unfortunately, we need to clarify if this is new or new to you?

Next the same question with the shift motor. Is it new or used?

Have you tried using the shift motor off of your old transfer case? Obviously, I don't know the status of that one but based on your comments, I am assuming the old transfer case was failed internally and most likely the shift motor was still operational at least for testing purposes. If the new T-case works the same way with both shift motors then I would assume there is an issue internal to the case. This would be where it is important to know where it came from. If it is brand new, then I would be calling back the store that you bought it from and seeing how they want to handle it.

Just because your tech can engage the transfer case fully by using his hand does not fully eliminate the shift fork, lock up collar, and other components internal to the transfer case. However, it does point primarily to the shift motor itself.

Let me know the questions above and we can go from there. Thanks

Great information. Thank you for closing the loop for us. Solutions to these issues will greatly help others. Thanks again.