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With the Shift Motor removed from the transfer case and the truck in neutral I am only able to move the shaft manually from 2W and 4Hi but I can't get it to go up to the top setting of 4Lo. It will move counter clockwise up to the 4Lo area but springs back and won't stay. In my testing I've noticed this and wonder if it is normal or a problem with the transfer case. Thoughts please.
It may be normal since the t-case really needs to be turning to shift. Try it again with the rear shaft disconnected, the hubs unlocked, and the transmission in Neutral, and spin the rear output shaft while you try to shift the t-case.
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