Pulling 4x4 hair out.

2009 dc 6 speed. I am getting the blinking green 4wd when turning on 4hi. I've tried a number of tricks. Back up, straight wheels, off and on, drive a few miles, etc. I just bought the truck and previous owner prob didn't use 4wd often as we just don't get the weather here in TN/GA.

Long story I have researched to no end. So today took ten mins and pulled the front diff actuator thinking I may had bad motor connection. This was not the case. All looked good. Could even see a fusion weld from tabs to motor. Check continuity at the motor terminals and legs to the connector prongs 1-2 and was good. Took 12v to connector terminals and motor works both + and - reversed. Assembled to try to see motor move fork. Was a no go. Pulled back apart. Fork seemed stuck. Moved it by hand which was hard at first. Then it freed up. Nice right? Reassembled and tested unit again. Ran it in and out with 12v a number of times. No problem. Reinstalled in the truck. Ugh. Still blinking and no 4wd. So I drive it thinking the slider isn't 1:1 with both axels. Nope still nothing. So I check the switches at the t case and pull the ball switches out. None stuck and function well as intended. Checked this by continuity test.

Weird thing is. Rolling on the fly I can put in 4hi and light flashes. No 4wd. Turn it off at 4wd switch and stays flashing until key on off reset.

Any ideas? What am I missing? With motor off and key on I can hear movement from the t case it sounds like.

Sorry for the long spill. But I'm running out of ideas.

 

Not to sure if this will work but when I first had mine id push in the clutch and it would blink but not engage. I have to really slam the clutch in to make it transfer. Sounds dumb but might work. Mines an 06 5spd though.

 

I'll try again. Have slammed it number of times. I know it's clutch switched because if I push clutch in and put in 4lo it will blink and beep when letting off the clutch an inch.

Thanks for the reply.