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This is a 2002 Excursion. The transfer stopped shifting into 4wd. I unplugged the two wire connection to the motor and plugged it back in and it began to work. A couple of hours later I tried again, same problem and same solution. The connections APPEAR fine. The voltage to the 2 wire connector seems consistent. If I swap between 4Hi and 4Low I see a 12V signal to the motor.
I really need to be able to reliably shift between 2 and 4wd for the next week or so. Even if I have to crawl under there and do it manually. Can I remove the motor and leave it off to shift it? It will only be on the road.
Also, How do you remove the multi-pin wire on the tcase? I slid the red keeper back (it is a keeper isn't it) but the connector still didn't seem to want to come out.
It might be as simple as disconnecting the plug at the motor and taking a pair of long nose pliers and just twisting the pins a hair. Just enough to take care of any gap between female plug and male pin.