[Scott05 tahoe]

I have found that a lot of the 4x4 issues on these early trucks are the cause of the front actuator a very rarely have problems with the transfer case control module or the switch

 

[Scott05 tahoe]

Did you clean the grounds.if so. Check the 4wd or trak fuse under the hood

 

[Scott05 tahoe]

My 04 had a fuse under the hood that was only like a 5 amp if I remember correctly. Are you 100% sure that the transfer case motor is okay mine would make noise but it wouldn't shift any gears and the last thing I can tell you is YouTube how to use a digital voltmeter and ohm out the switch to make sure it is good I've seen new ones come bad

 

[Scott05 tahoe]

There's also some ground wires up by the front actuator too in that area to the frame if you look under I believe you can see them

 

[Scott05 tahoe]

We'll get it figured out there's only four parts to the whole system

 

[Scott05 tahoe]

Definitely possible