Hello everyone.
I'm having some issues with my 4x4 on my 2006 fx4 lvl2.
Last year my transfer case shift motor was acting up and after already opening it up and cleaning it multiple times it was dead. I purchased a rebuilt motor from summit but it took forever to arrive so I had run my truck without the motor so that I could still use my 4x4. When my new motor finally arrived the plug on truck side was corroded and had a broken pin. Ordered a pigtail and wired it up with butt connectors and had everything taped up. Installed the new motor and finally had shift on the fly abilities again. Used it all summer without issue. Now getting into the snowy season and I try to use it and the problems come out. I shift to 4H I hear the relay click and the light comes on but the front wheels don't engage. I shift to 4L relays click, I can hear the transfer case shift and 4L light comes on and the front wheels engage. Shift back to 4H and still no front wheels. Shift to 2 I hear the relays clicking multiple times and takes a bit of time before the light finally turns off. I found some links to the ranger station about resyncing the motor and I've tried adjusting the sensor on the motor. After adjusting I was able to get 4h intermittently after going from 4L to 4H but after moving 50 feet I'd hear a big clunk and no more front wheels. I'm at a lose. I'm looking for where I should go from here. Not sure if I should try a new motor or if I should redo the wiring to the plug or if I'm missing something and should look else where. Hopefully someone will have some advice for me.
Thanks in advance.

 

The Ranger 4WD system changed over the years but what didn't change was the way the shift motor works with what ever "electrics" they changed to.

Borg Warner(BW) electric shift transfer cases have shift rod that needs to move 270deg to go from 2WD to 4Low
So starting at 2WD 0deg
4High is 90deg rotation counter clockwise
Neutral, yes Neutral is there, is 90deg more counter clockwise
4Low is another 90deg counter clockwise

Image of this here: 1354transfer.jpg Photo by jds3403 | Photobucket
Shift rod is pointed at 2WD, neutral is opposite 2WD

Shift rod can't move any more counter clockwise from 4Low, so to go back to 2WD it has to rotate clockwise 90(Neutral), 90(4High) and 90 again(2WD)
So 90 + 90 + 90 = 270 deg, so can take a bit of time

Now on the shift motor are 2 power wires, it is just a DC motor so reversing + and - reverses direction the motor turns, clockwise or counter clockwise.
And that assigning polarity to these wires is done by relays, that's what you hear clicking in the dash when you select 2WD, 4Hi, 4Low, relays powering the shift motor

But how does the 4WD system know when shift rod is in correct position for 2WD or 4Hi or 4Low.
That is what the other 5 wires are for going to the shift motor.
Inside the shift motor is a contact wheel and 5 contact pins, as the shift motor turns so does the contact wheel, when X1 and X3 contact is closed and X2 and X4 are open then shift rod is in position for 2WD, just an example, lol, but you get the idea

When you Sync the shift motor that's what you are doing, you are rotating the contact wheel so 2WD, 4hi, and 4low on the motor and in the transfer case are lined up and correct.

The 4WD lights on the dash are actually turned on and off based on this contact wheel.
So if light on dash says 4High but you are NOT in 4High then either contact wheel is not synced to transfer case shift rod or there is a problem with transfer case itself.

There were several types 4WD control modules over the years, even GEM module did it for a few years.
But the shift motor designed stay pretty much the same.