I had the same issue with my 05'. Service 4wd everytime it would piss rain for a few days straight (and thats a lot here in BC!)Used this tutorial and she's good as new...

HOW TO CHANGE ENCODER MOTOR/SENSOR

I "forgot" to put my transfer case into neutral so when I took it apart I marked where the gears were lined up and made sure to put it back exactly so as it is a timed gear. Took about an hour and a couple beers.

 

Yeah that is the write up I was looking at. But I'm replacing the encoder motor with an entirely new encoder motor, not just replacing the sensor. I think everything says you can turn the shaft on the transfer case but not on the encoder motor. I'm just not sure if it clicks into place for each setting and which position would be neutral.

Right now my plan is to jack up the truck, take the old one off, turn the shaft to what looks like would match the new motor because it should be in the neutral position. Turn on the truck and put it into drive (on jack stands) to test that it's in neutral. I'd rather not do that since the drive shaft will be off and it will put it out of alignment if I get it wrong. But I'll have it marked so I'm pretty sure I could get it turned back if I needed to.

 

Hmm ya not sure on that either. Are you sure the whole motor is shot? Be a lot cheaper to just put a new sensor and gasket in it. From what I understand thats usually the issue, and was for me.

 

New to this board and I have a dumb question I just bought a new to me 2005 seirra 1500 the encoder motor was already removed prior to me getting it .I have a boneyard one the only issue is that the clock position on the transfer case is not the same as the one on the encoder as I sit here scrating my head how does one go about aligning the transfer case so that they match

Thank you
Bootlegger

 

I haven't done it yet, but I've read that you can just turn the shaft coming out of the transfer case. Do not turn the female end in the motor or you can damage it. If it is tight to turn I heard turning the rear drive shaft (just the free play) can take the stress off it. Also, careful not to damage the shaft, use a cloth or something when you put the pliers on.

 

Figured it out. Before you attach the motor, just connect the connector (make sure you have removed the plastic protector piece that it ships with that keeps the motor in neutral). Turn the key to the on position, shift the truck into neutral and push the button for the original gear you were in (in my case 2 Hi). This will shift the motor into the correct position for your TC shaft and you can install it. You will hear the motor then and see the lights on your switch change from neutral to the desired position. If it didn't work, check your manual for proper procedure to take your TC out of neutral via the switch. I saw on an older one you had to press 2WD Hi then turn the key off and back on.

 

Awesome thank you

will have to give that a go tomorrow will let you know how that works out

cheers

 

Good evening all
just a quick question would any of you fine folks have a wiring diagram of the 8 pin connector at the sensor motor I need to figure dthe colour codes so I can bench test my encoder

Thank you in advance

 

If I'm replacing my whole encoder motor in my truck is already two wheel drive well if it correctly or do I still have to put it in neutral