So my 2004 was stuck in 4H. I could hear it trying to switch when going to 2H. It would make noise then stop, then make noise again, and stop, doing it a couple more times, never actually shifting to 2H. I ordered a new transfer case shift motor and replaced it. When I did it, I could see the transfer case shaft was set at 4H so I turned it to 2H so it would line up with the new motor. After I got it all buttoned up and drove a bit to ensure was in 2wd, I then tested the old motor and applying 12v to the motor leads turns the motor and the coupling, and reversing polarity reverses the motor and coupling.

Now I am wondering if the old motor was really bad. Maybe the sensor in the coupling? I have not tried to go to 4H then back to 2H cause it is about to storm and I need the truck for tomorrow.

Any thoughts from the forum?

 

One common scenario
The plastic pads on the shift fork broke off and now it either will not shift or has trouble shifting

 

I was able to turn the shaft of the transfer case with just my fingers to 2H. It moved very easily

 

That means the 4x4 fork should be good
Some go into 4 low and won't come out when that low range fork loses its plastic pieces
Might want to check the low range too

 

just curious, how frequesntly had you been using 4x4 prior to these problems ?

 

Very rarely. I found it was not going into 4wd about a year ago when I was pulling a boat out of a backyard that had sat for a few years. Wanted to ensure better traction. It would not go to 4H, but was able to getthe boat out anyway. At some point this past year I decided to look into why 4wd did not work. I found one of the 2 vacuum valves looked melted and wide open on a side so was not working obviously. I ordered a new one and while replacing it, I broke a vacuum coupler. Found one of those and replaced it too. Still would not go to 4wd. Forgot about it for a bit and the other day I decided to try again. Got a new solenoid and replaced it. Started the truck and it was in 4H with the **** in 2H. Would not shift back to 2 and here we are. I replaced the motor and manually turned the shaft back to 2 and have not touched it since. Will test it out this weekend