I tried searching for this issue, but no luck, pretty sure it was my search words, so sorry if this question has been posted before.
I recently changed out my transfer case with a 4:1 adventure model and now I'm having an issue where it is "switching" engaging in the 4 Hi lock mode. I notice it when pulling into or out of a parking space, the turning gets really stiff. I've switched the servo motor for the changing the transfer case modes, and also checked the operation of that piece by switching the modes with the servo off to check that it is turning correctly. Both the old one on my other transfer case and the one on my adventure case moved to the same points. I also switched modes several times (4 hi lock/ 4 lo lock/ neutral) and while stopped and moving slightly as the owners manual recommended. Also drove backwards while turning again as the manual recommened.
It doesnt' seem to be always locked in, but locks up time to time. Also no errors codes or issues with switching the modes. The history of the case I put in was a used one purchased from a wrecking yard, all looked fine with it, and it had less then 50k miles on the doner vehicle. Also from the same year (2007). Is there any reprogramming needed to do this swap or do I have a faulty transfer case?
Any feed back would be appreciated.