BW1354 doesn't consistently shift into 4H/4L

[RangerReviver1990]

Today I installed a new shift motor for my transfer case, got it all nice and snug and went to go see if it go into 4H/4L and it did the first couple times, then it wouldn't. Thought that was kinda odd, pressed the 4H button a couple more times then it'd shift into 4H but not 4L. So I took down some dirt roads to play with it and see if it'd shift, eventually it shifted into 4H when I wasn't paying attention so I stopped the truck and put it into neutral to shift into 4L and it made a grinding noise, paused then it made the grinding noise again and then both lights switched off and apparently went back into 2wd. I'm kinda suspecting that my little module behind the rear seats is going bad or I didn't connect something correctly. I'm kinda stumped at the moment

 

[pjtoledo]

quick reminder: simplified version
the shift motor only loads a big spring when the shaft is turned.
then, when gears and whatever align the spring pushes them into engagement.
big spring for hi/lo, small spring for front axle engagement.
check a parts manual for detailed info.

when switching between hi & lo there is a narrow gap where neither are engaged, that's a neutral position in the Tcase.

 

[scotts90ranger]

It could be the alignment of the potentiometer on the shift motor, it's been a while since I looked at one but I know it is adjustable... I know back in the day people would get creative with the rubber stop in the 2WD position which if it wasn't all the way there it wouldn't do anything...

Unfortunately that's about all I know, I've only had a couple with the electric cases, one I gave up and was half way through converting to manual when the relationship ended and I lost the rig...

 

[Curious Hound]

Sounds like the switch contacts need adjusting on your shift motor. It is not a potentiometer. There is an assembly of switches with sliding copper contacts that tells the controller what position the shift motor is in. You can loosen the screws holding the switch cover on and rotate it slightly to fine tune the adjustment.

This may be helpful so you know what's going on there.