06 Will not disengage 4wd HI, ECU clicking

I think I'd jack up a front wheel first to to eliminate driveline bind and make sure the transfer case is indeed still physically in 4wd. Maybe you will get lucky and it's just a faulty switch.

If you do pull the actuator make sure the big gear stays in the transfer case side so you don't lose the timing.

 

Your issue seems to be here

 

Still trying to figure out how the TL switch are in 2WD position. Yet the 4WD detection switch is not correct. Gear slippage would have to occur. That is if the shift rod is in the 4WD position. Either the transfer case is in 2WD or we have internal issues with the actuator or a failed 4WD detection switch.

 

Okay, duh. I did take the cover off this one because the vent tube was loose. There was some water but little to none corrosion.

 

Correct, it will not unlock the ADD until it sees the transfer case shift (4WD go to 12v).

We know the actuator moved and compressed the wait spring because TL1 TL2 and TL3 are correct for 2wd but the shift fork in the transfer hasn't physically moved according to the 4WD switch.

 

Good copy. What's my next move you think? LOL, I'm just trying to not screw it up anymore.

 

The actuator can move independent of the shift rod because of the "wait" spring, once the rod is free to move the spring pulls it to match the actuator.

 

I think first lets get a front wheel off the ground so we can eliminate any driveline bind and confirm we are physically in 4wd.

If we are then we're gona have to pull the actuator cover and see what we can see, I'd put the switch to 4wd first and cycle the key to hopefully eliminate any spring tension on the actuator before taking the bilts out.
Also try to make sure the big gear stays in place so you don't lose your timing.

 

Just for reference this is the wait spring mechanism I'm referring to.

 

So, I pulled the cover off and the damn spring mechanism came out too, along with some fluid. I was able to get it back in and manually moved to what I thought was 2wd. Ta-da, back in 2wd. I switched it to 4wd, good. Then, I moved out of 2wd...good! The freaking gasket cracked so I'll need to get another.

 

Plastic gears compress that big spring. LOL
Must be some good plastic.....
So far, we haven't seen gear teeth failure.

Anyways, it makes sense now.
The spring stores energy to move the rod once the rod is in the "correct" position to move. (AKA - not in a bind)

 

Hey.....NICE.

No parts required fix.
I'd think RTV can be used in place of the gasket.
But you can buy a gasket if it's easier for you.

 

Do you think it got stuck under pressure?

 

I think I'm go by & pick up RTV. I'd eventually like to make ADD as water tight as possible too.

BIG thanks guys!

 

Not sure what would have caused it to stick, it's nothing more than a gear that moves a rack which moves the forks in the transfer case.

 

I'd think if it did, you would have heard/felt it when you took the actuator off.
I mean, you said the spring fell off? So possibly.

Either way, i think you fixed the issue. There was a bind in the actuator somewhere.
You got the bind out.

 

It's not a super stout spring but it does have some tension behind it.
I can't say that I've ever seen anyone that had a stripped gear so aparently it works.

 

Yep, just looking to future. Over 200k miles and she's still my baby. Hopefully it won't break soon. LOL

 

Just keep changing the fluids in it regularly.
You should be good for 300-350k. That's when the the timing chain seems to stretch enough to cause codes.
Other than that, it's usually frame failure.

 

I saw no gear wear. I need to add some more lithium grease as there was some water.