[SOLVED] 1999 Tahoe Transfer case shift motor - front diff not engaging

[pedub]

Hello all, 1999 Tahoe Z71 5.7 replacing transfer case encoder motor, took the old one out and now can't get new or old one back in? new one came set to 2 wheel high and that's where the transfer case was, I've been driving it for a few months, I shifted the transfer case with a wrench just to see, and it did shift. this has the double D shaft not the spline, still won't line up, put the old and new motors on the bench side by side and everything looks the same. had the truck in neutral and in park. is the motor off or do I just need to try to move something else? it seems close but won't sit flat before putting the bolts in? and Can I plug it in and shift it with the Buttons with the motor out of the transfer case, old motor has a sticker that says not to but have seen videos were people have done it, and it worked? thanks for any help.

 

[Fless]

New transfer case motors usually come set to neutral. Are you re-using the plastic gasket?

 

[pedub]

New transfer case motors usually come set to neutral. Are you re-using the plastic gasket?

I got it in and it works, I can hear it shifting and the each of the lights on the buttons light up when engaged, goes into low etc. but front differential still don't lock up, this is after having the differential changed a while ago, I put a front actuator in and it still had no 4x4, now just put the transfer case shift motor in because it got stuck in low and I finally got it into 2 high and drove it like that for a few months(only vehicle) so now I'm trying to get the 4x4 to work again. sorry for being all over the place. maybe a wire from the front differential? or that front actuator was junk outa the box?

 

[Eman85]

Check for power and ground at the actuator.

 

[Fless]

Pull the front diff actuator and let it hang. Switch from 2HI to 4WD to see if it extends. At this point you can also check power and ground at the actuator connector.

You can find wiring diagrams and ground locations at www.charm.li. Let us know how it goes.

 

[pedub]

Pull the front diff actuator and let it hang. Switch from 2HI to 4WD to see if it extends. At this point you can also check power and ground at the actuator connector.

You can find wiring diagrams and ground locations at www.charm.li. Let us know how it goes.

Will Do

 

[pedub]

Hi Guys, well front diff will not lock up, have 2 actuators and both work (tested hanging) also tried to push on the inside where the actuator goes and spin the tire, won't engage? all the lights in the truck work 2hi,4hi I can hear the trans motor working etc. when 4hi is on it thinks it's in but it's not. everything is working but the front diff. and I did run another ground wire, so I know it's got a good ground and power to the actuator. I guess I got had when I bought that junk yard differential. how does that pin or whatever inside work?' I hear people call it a fork. (that the actuator pushes on) is there anything a guy can fix in there? I'm not putting another front diff in. thanks for all the reply's

 

[Eman85]

https://g.oempartsonline.com/v-1999-chevrolet-tahoe--lt--5-7l-v8-gas/front-drive-axle--differential
Here's a diagram. Linkage is all in the tube. Are you saying with the actuator removed you can't engage the axle by pushing on the fork?

 

[pedub]

https://g.oempartsonline.com/v-1999-chevrolet-tahoe--lt--5-7l-v8-gas/front-drive-axle--differential
Here's a diagram. Linkage is all in the tube. Are you saying with the actuator removed you can't engage the axle by pushing on the fork?

Yes, it pushes in maybe 3/8 and doesn't lock in. do you think it could be rusted together? I watched a video on someone rebuilding one and see how the fork works and I was reading another thread on here and a guy had the same problem, last thing he said was he was going to put in a new TCCM. I don't think that will help. I will try to look him up and see what he ended up doing. thanks

 

[Eman85]

When you push on the fork you would need to rotate the axle slowly to het the splines to line up and lock together. If pushing on the fork doesn't lock the axle in you have a mechanical problem, not electrical. They used to make an actuator that used a cable to make it manual, don't know if they still make them.

 

[pedub]

When you push on the fork you would need to rotate the axle slowly to het the splines to line up and lock together. If pushing on the fork doesn't lock the axle in you have a mechanical problem, not electrical. They used to make an actuator that used a cable to make it manual, don't know if they still make them.

I was pushing in and turning the driver's side wheel, would it matter which wheel I rotate? I'm grasping at straws now I know, I had the truck on 4 stands and had it in drive 2hi /4hi and the front wheels never engaged, well I guess it's a 2-wheel drive truck now. thanks for all the help

 

[Eman85]

Yes, turn the pass. side wheel so it turns the pass axle that it is trying to engage.

 

[pedub]

Well, I can't stand it, I gotta pull it apart, let you know what I find out

 

[pedub]

so, I finely pulled it apart and the washer that sits on the shaft for the slip gear somehow got wedged in between the 2 gears? keeping it from engaging the 4x4, how the hell did that happen? I put another carrier in the truck and will keep this one for parts. thanks for all the help.

 

[Eman85]

this is after having the differential changed a while ago

This is how it happened, human error.

 

[pedub]

Had to be