Hey Chad,
Sorry i am just seeing this message. I disassembled the motor housing as much as i felt comfortable. The cause of my whole issue seemed to be that the motor somehow over-wound and was stuck. When i dissasembeled and reassembled it worked only for one cycle of movement because i had not reassembled it correctly. Once you can isolate that motor and play with it by giving it power to the correct pins you will be able to figure out how the limit switch gear is to be placed when assembling.

The easiest thing for me to convey to you is that if you slip that electric motor / actuator off and you are able to pull / push the rod that engages the front driveshaft; as well as be able to confirm that the front driveshaft is engaged by it not being able to freely spin.... The issue is without a doubt that electric motor.

Let me know how it goes!

Hi there, I saw your post about the 4WD transfer case actuator in this thread and wanted to follow up:

http://wwwl.yotatech.com/f2/4wd-wont...1/index10.html

Sounds like I'm in your exact position with my 02 4Runner Sport, I took the actuator cover off andit seems to me like the little motor that drives the shaft may not be working. I'm thinking about trying to take the motor apart and playing with the shaft to see if I can get it working. Is this what you did? Any advice?
Thanks.
Chad