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?