Hmm, some colors are sure to match up, or that is at the TCCM? At the encoder motor on the tcase, it's an 8 pin connector utilizing 7 pins. RED, ORANGE, TAN and BLACK are 12 or 14 gauge, with a dark blue/white, brown/white and green/black 20 gauge wires. The connector pins and wires coming off the backshell are all good, with the right amount of dielectric grease in there. So the grn/blk is the reference voltage, and when disconnecting that plug and starting it up, probing that gives 3.95V and it drops off to low after 4WD codes trigger...I tried testing as per the 2002 and older method with it disconnected but I wasn't getting good voltage drops on anything really...maybe the TCCM is dropping it's signals when that is disconnected?
Anyways, I went into it further with the tech 2 and noticed the following:
Pulling the TREC CB and resetting the TCCM triggers three ATC codes:
C0306 - Motor A/B circuit malfunction
C0321 - Tcase lock circuit malf.
C0327 - Encoder circuit malf.
After erasing the codes, if it's in park, no 4WD codes trigger but in neutral, C0327 returns.
On the data screen I'm getting:
Encoder supply: 5.09V, and that holds steady ALWAYS
Encoder return: 4.08V, varies a little but good and stuck at the 4hi voltage, even during switch commands...so the encoder motor seems to be reporting the correct gear back to the TCCM (and it's definitely stuck in 4hi, I can hear the front driveshaft engaged as well as the front half shafts.
Mode switch return: 0.51V and during switch command delays or motor calls, that voltage stays constant. I'm unsure what this means, if that is normal or what?
In 4hi, it shows tcase lock disabled and when switched to auto 4wd, shows tcase lock enabled. Both modes show front axle requested as YES.
When going into the tcase function menu, all lights and button selections work, transfer case lock mode works.
When ATC motor A or B control is activated, I get this error: "Motor control attempted within 10 sec of previous control" no matter how long I wait. The tech 2 displays -50% motor load when turning ON either circuit, and -5% when selecting OFF.
Of note: When I trigger motor control, I can faintly hear the motor turning, with no grinding noise or clunks, until the error message displays.
I also, of course, inspected the two output shafts for play, leakage and damage but they are just fine. I also checked the fluid and it's a nice blue color at the fill hole. No sign of leakage anywhere on the tcase or trans either, just the engine rear main seal leak.
It's probably something in the encoder has gone bad IMO, as you all are saying, but with hearing the motor rotate and getting that error, could it possibly be the motor shaft is sheared off somewhere? It's too dark to pull the driveshaft and remove that encoder, I'll have to do it tomorrow. Let me know if after seeing all this info, if that just reaffirms the encoder motor or possibly something else? I wish this thing was a 241 or better yet, a 205! lol.
