So I haven't had 4x4 in my truck for almost a year now. Figured out that my GEM module is bad and the transfer case motor is also bad. I've already bought and installed the 4x4 posi-lok and now I'm just needing to make a part for the transfer case. I've already tried buying the shiftster but it seems like he that guy doesn't sell those anymore. I have access to someone building that type of product at a machine shop, I just need to figure out how the gears in the t-case line up when you turn the shaft on the back of the case. If anyone has that shiftster product or knows about the BG4406 t-case that would be great. Winter is here in California, and I'm planning on going up to the snow pretty often. Thanks for you help!

 

Had a guy from Dubai stop by (no s**T, really - he was on vacation and needed some Bronco parts because they can't get stuff there) anyway, he tried using the shiftster to solve his problem and it didn't work out, he could only get 4low and apparently that sucks in the sand, you need 4 high.
Upshot is we found him some bits and did a little research online - apparently there is a little end stop in the shift motor that gets worn, the motor goes a little too far, and the shift computer gets "lost". I understand that you can replace that little end stop, or sometimes just flip it over and get the unused side working.
Might be that simple.

 

Hmmmm haven't even thought about looking at the motor. I'll check this weekend. If I can just get the motor to work to switch it into 4x4 electronically that will work. I'll just use that posi-lok to engage the front end. Thank you!