I was able to troubleshoot the issue. I firmly believe that the issue is the High-Low sleeve inside the transfer case. Reference photos. The actuator looks just fine. I was able to slide the rod/sleeve back into Low position with the transmission in neutral. Then I went for a drive around the block (with the actuator removed) in essentially 2wd low. It drove fine. No grinding and Reverse worked as normal. I then attempted to push the rod all the way forward to the High position. I can't push it past the 5th tooth. The YT videos show approximately the 4th tooth aligned with the bushing, so I don't believe it's going all the way forward. I reinstalled and retimed the actuator so that it would push the rod forward slightly. It will drive forward just fine (I didn't go faster than 7mph) but it still grinds in Reverse and Neutral. So....yeah pretty certain it's the High-Low sleeve since I can't even push it all the way forward by hand. Sidenote - my actuator doesn't have a position switch. I also noticed it is also missing one electronic pin at the plug. I did clock it forward and it timed itself to the normal position with the key on, so this appears normal. Anyone crack open the TC on here for a rebuild, or do most people just replace them? Cheers, Dewey
