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So about 6 months ago I had a flashing OD light, Tranny would start out in 2nd gear basically. I replaced ALL the sensors that normally cause this and no help, then I read on here a bad battery connection or weak battery etc can cause this also so I replaced a battery which I knew was old and it FIXED everything. Fast forward to 2 weeks ago, I noticed a vibration in drivetrain somewhere, climbed under truck and found Tcase bolts all backed out.............?? no Idea why but It was so I tightened all the bolts back up and NOW THE OD LIGHT IS FLASHING AGAIN THE SECOND I DRIVE IT OUT OF MY GARAGE AFTER TIGHTENING TCASE BOLTS!!!...........Only thing I notice is that my 1-2 shift is a little harder than I remember, but other than that OD turns on and off just fine and its shifting just fine............WTF???
And a tuner, I have noticed the trans problems and tuners go hand in hand quite often.
Have you checked out the frayed wire in the steering column problem many have had?
If wrenching on the transfer case caused a light have you got under the truck again and checked wire connections and looked for wires rubbing and grounding out somewhere on or around the trans?
Sometimes water can get in the plugs and cause weird things. I would pull them all and check them and put some dielectric grease on all of them.