99 2DR NP246 'Stuck' with noises coming from Transfer Case

[no cigar]

Fresh rebuilt NP246. After switching to 4Hi and hearing a ping or pop from the case, it is 'stuck' in 4Hi an will not return to 2WD or 4Lo. New switch was installed along with new encoder motor at the time of install. Usually ran it in 4Hi for a little bit every week to move things around - but this time it seems to have gotten stuck. When pressing the 2WD button on the switch, there are 4 audible clicks along with the sound of the encoder motor perhaps? trying to operate. After the 4th click the light on the switch stops blinking and remains in 4Hi. Truck drives and doesn't 'feel' as though it's in 4WD.

I recorded a short youtube video of the noises. Any thoughts?

 

[no cigar]

Bump... Any ideas?

 

[Fless]

I would probably remove the encoder motor and see if I could shift the T/C manually back into 2wd, neutral, etc., or if the shift shaft will even move. That might tell you if it's a weak encoder motor or something inside the T/C.

 

[exp500]

I agree with remove encoder to test tcase shifting. Driving with disconnected encoder ok for test. You can "run" the encoder while mechanically disconnected from tcase with a ground wire alligator clipped to tcase and encoder. Sometimes have to do it to find the "home" spot for installation.

 

[chicagochuck]

My tcase was stuck in 4Hi or 4lo I can't remember, but I could hear the Tcase motor and a clunk noise trying to disengage, but It would not come out of 4HI. I ended up jacking up the back tires off the ground I pushed 2HI and it worked. I don't even hear any clunk from your video but I thought to at least share.