NEED HELP Help with AWD not disengaging 2006 AWD Rainer. 4.2L 255k miles

[TBgonzo]

Encode was bad replaced with low mile OEM, AWD road tested good several times then the last time tight turn on dirt gassed it, it grabbed and now acts like a 4x4 when turning, pulled off motor which took some wiggling to get off, manually shifted T case, reset motor , its working but for how long? Tcase fluid clean full, correct fluid. What would cause it not to return/release? NoTcase codes

 

[mrrsm]

Review the PDFs for Information and Diagnostic Troubleshooting ideas.The Two Images will assist you with using a DMM to perform Electrical Diagnostic Work:

Visit THIS Link as well...

TRANSFER CASE STUDIES: DIAGNOSING GM’s 4WD SYSTEM - … / transfer-case-studies-diagnosing-gm-s-4wd-system.pdf / PDF4PRO

front axle motor actuator next. Using a voltmeter, I determined 0 voltage was present on terminal C, (circuit 241, brown wire). I chose this wire based on the wiring diagram, which showed fuse 24 in the IP fuse box feeding voltage to the front axle motor. Going this far without first checking...

pdf4pro.com

A Practical Diagnostic Approach (Ignore Physical Differences...it is the IDEA of How to Discover Problems and a Hands On View of the Environment) :

 

[Mooseman]

Two with the exact same problem within a day at opposite ends of the planet.

Please ignore @mrrsm 's post as you have the non-selectable AWD system. Not the same system as the one with the regular switch selectable 4x4 system.

Are you getting crow hop while making a sharp turn on dry asphalt? Maybe not allowing enough time for the AWD to disengage?

Is the service AWD system light coming on? Are you able to scan for codes on the system beyond what a cheap scanner is able to scan? What brand and model encoder motor did you get? It might be possible that you got the one for the selectable 4x4 system, which incorporates a brake that the TCCM would not know how to handle but I think the connector might not match (two less wires).

After engaging, it should slowly disengage on its own and re-engage if it detects slip again. Without the internal brake on the encoder motor, the transfer case just slowly moves back to the disengaged position.

Another thing I just through of. If there is a good difference in tire size front to back, the TCCM might be constantly engaging the front wheels thinking there is wheels slip. It uses front and rear output shaft rotation speeds to detect slip. Do you have a scanner capable to looking up the front and rear shaft speeds?

 

[Beacon]

I don't know why these vehicles get stuck in 4wd, my does all the time. I have replaced several encoder motors, did consecutive transfer case fluid charges, front diff fluid. Nothing fixed it. But what I'm almost certain of, you have a bad steering wheel position sensor. And, pushing the button on the underside or your gear selector, to turn off traction control will prevent it from getting stuck in 4wd. Do this as soon as take it out of park, and only use it if you truly need 4wd.
Also the next time I decide to replace the encoder motor it will be OE, NOT DORMAN