Case locked into 4lo and had to remove shift motor to disengage now i can not get the shift motor to go back on because the shaft will not line up with the motor

Does placing it in neutral put the entire drive in neutral???? Yes . Taking the vehicle to a qualified repair shop that has a factory or professional scan tool to read code's in the transfer case control module is what you should do , you probably have no clue of the complexity of these 4X4 systems . How many buttons on the switch on the instrument panel ?
The BW 4493/4494 transfer case features a 4-button shift control switch (1) located on the instrument panel. When the vehicle has the ignition key in the RUN position, the transfer case shift control module starts monitoring the transfer case shift control switch to determine if the driver desires a new mode/gear position. At a single press of the transfer case shift control switch, the lamp of the new desired position begins flashing to inform the driver that the transfer case shift control module has received the request for a new mode/gear position. The lamp continues to flash until all shifting criteria have been met and the new mode/gear position has been reached, or has been engaged. Once the new mode/gear position is fully active, the switch indicator lamp for the new position remains ON constantly.

During normal driving situations, the transfer case operates in the 4HI mode. When the 4HI mode is selected, the transfer case shift control module sends 12-volts to an electrical motor, which is the transfer case encoder motor. This motor rotates the transfer case shift detent lever shaft which moves the shift forks and range sleeve to obtain different modes/ranges.
The BW 4493/4494 transfer case has the added feature of also providing the driver with 3 manual mode/range positions:
• 4HI - 4-Wheel Drive High Open
• 4HI Lock - 4-Wheel Drive High Locked
• 4LO Lock - 4-Wheel Drive Low Locked
The driver may choose to select any of these mode/range positions while driving the vehicle. However, the transfer case will not allow a shift into or out of 4LO Lock unless the following criteria has been met:

DTC B0790 Transfer Case Neutral Indicator Circuit Malfunction
DTC B2725 ATC Mode Switch Circuit Malfunction
The mode switch circuit consists of 5 modes. The transfer case shift control module supplies a regulated 5 volts, DC to the switch through the 5-volt regulator circuit. The current travels through the resistor of the currently pressed mode button. The current is then returned to the transfer case shift control module through the switch signal circuit.
The transfer case shift control module constantly monitors this signal voltage to determine the condition of the mode switch circuit.
When each of the modes are selected they will complete a circuit through their own specific resistor while the button is pressed. The transfer case shift control module continuously monitors the switch input to determine whether the Neutral, Differential Lock, 4HI, 4HI Lock, or 4LO Lock mode was selected by the driver.

DTC C0306 Motor A or B Circuit Malfunction
The transfer case motor is a bi-directional, permanent magnet, D.C. motor. When energized, through motor control A or motor control B, the ground is provided by the opposing motor control circuit and then grounded through the transfer case shift control module ground circuit, the motor, through a series of gears, rotates a shaft which moves the mode and range forks to shift the transfer case between the following ranges:
• 4HI
• 4HI Lock
• 4LO Lock
• Neutral
This DTC detects an open, short to voltage, or short to ground in the motor control A or motor control B circuits, or an open, or short to ground inside the motor.

DTC C0327 Encoder Circuit Malfunction
DTC C0329
DTC C0359
DTC C0550

The Borg Warner (BW) model 4493/4494 NR4 transfer case is a 2-speed, full-time 4WD, transfer case. The transfer case has an external planetary type differential, which has 2 different sets of pinion gears. The planetary differential provides a 40/60 torque split front/rear full-time. This means the front and rear propeller shafts are constantly being driven for maximum traction in all conditions. A high/low planetary carrier assembly provides the high and low ranges, which is a 6-pinion gear, sun gear, and annulus gear arrangement, giving a 2.64 low range reduction ratio in the BW 4493 and a 4:1 ratio in the BW 4494.

Which do you have ?
Transfer Case - NVG 236 (Two Speed Automatic)
Transfer Case - NVG 233-NP1 (Two Speed Selectable)
The NV236 transfer case is an automatic transfer case with three drive ranges. Shifting from rear wheel drive to four wheel drive is done automatically when the transfer case shift control module receives wheel rotating slip information from the speed sensors. The transfer case shift control module then engages the transfer case motor/encoder to position the transfer case from rear to four wheel drive. When the transfer case shift control module receives information that the wheel rotation is the same on both axles, the transfer case shift control module sends position information to the motor/encoder to put the transfer case back into rear wheel drive. The three drive ranges are 2HI, 4HI, and 4LO. The 2HI position is for normal driving with the rear wheels pushing the vehicle. The 4HI, position is for driving through sand, snow, mud, gravel, or heavy rain at normal or slightly below normal speeds. The 4HI engages the front axle to allow for four wheel drive. The front axle is pulling the vehicle, and the rear axle is pushing the vehicle. The 4LO range is used for off road driving, heavy snow, deep mud, or shallow fording. The 4LO is similar to the 4HI except that the gearing in the transfer case is set for low speed and high torque. The NV236 is manufactured at Syracuse New York by New Venture Gear a division of New Process Gear for General Motors.
Is the switch light on or flashing ? If you have automatic 4x4 there are several DTC'S that can set >
DTC B2725 ATC Mode Switch Circuit Malfunction DTC C0300 Rear Speed Sensor Malfunction DTC C0305 Front Speed Sensor Malfunction DTC C0308 Motor A/B Circuit Low DTC C0309 Motor A/B Circuit High DTC C0310 Motor A/B Circuit Open DTC C0315 Motor Ground Circuit Open DTC C0323 T-Case Lock Circuit Low DTC C0324 T-Case Lock Circuit High DTC C0327 Encoder Circuit Malfunction DTC C0362 4LO Discrete Output Circuit High DTC C0367 Front Axle Control Circuit High DTC C0374 General System Malfunction DTC C0376 Front/Rear Shaft Speed Mismatch DTC C0387 Unable to Perform Shift DTC C0550 ECU Malfunction DTC C0611 VIN Information Error

Try shifting the transmission into neutral, then transfer case to 2wd.

You are missing out on vital information by not have a factory scan tool to check for DTC'S - diagnostic trouble code's & viewing control module data parameters , your going at this blindly an that never fixes anything . Also having factory service repair information so you know how it is suppose to work , and to view electrical diagrams .
DTC B0768 Service Indicator Circuit High
DTC B2725 ATC Mode Switch Circuit Malfunction
DTC C0300 Rear Speed Sensor Malfunction
DTC C0305 Front Speed Sensor Malfunction
DTC C0308 Motor A/B Circuit Low
DTC C0309 Motor A/B Circuit High
DTC C0310 Motor A/B Circuit Open
DTC C0315 Motor Ground Circuit Open
DTC C0323 T-Case Lock Circuit Low
DTC C0324 T-Case Lock Circuit High
DTC C0327 Encoder Circuit Malfunction
DTC C0357 Park Switch Circuit High
DTC C0362 4LO Discrete Output Circuit High
DTC C0367 Front Axle Control Circuit High
DTC C0374 General System Malfunction
DTC C0376 Front/Rear Shaft Speed Mismatch
DTC C0550 ECU Malfunction
DTC C0611 VIN Information Error
DTC C0895 Device Voltage Malfunction
Your best bet ,take it to a qualified repair shop .

The transmission control module and the transfer case control module are separate parts. The transmission control module is mounted under the hood and controls only transmission functions. The transfer case control module controls only the transfer case, and is located inside the truck. If you remove the trim panel under the steering column you will find the transfer case control module mounted just to the right of the opening.


The shift motor is located just behind the axle tube to prevent damage.There is a shift motor on the right front axle that is vacuum operated.
The shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor, a motor brake, a gear train and an analog position sensor. The shift motors' overall function is to move and lock a gear that moves the mode fork found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4LOCK and AWD). The operating current of the shift motor under
stall conditions is 30 amps maximum at 72° F with 13.5 volts, at the motor leads.OPERATION
Shifting in the transfer case occurs when the shift motor brake is released and a Pulse Width Modulated (PWM) voltage is supplied to the shift motor by the Front Control Module (FCM). A linear analog position sensor located inside the shift motor, provides the FCM with the motors' angular, rotational position. With this information, the FCM
continuously knows the motors' position, and therefore allows it to accurately control the motors' operation, including voltage polarity which is used to control motor direction.

REMOVAL :---Note: New shift motor assemblies are shipped in the AWD position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the AWD position prior to motor installation. Raise the vehicle on a suitable hoist.Remove the front propeller shaft. Disengage the wiring connectors from the shift motor and mode sensor.Remove the front output shaft companion flange from the transfer case.Remove the bolts (Remove the Shift Motor and Mode Sensor Assembly Bolts) holding the shift motor and mode sensor assembly onto the transfer case.Separate the shift motor and mode sensor assembly from the transfer case. See fig below:--
1 - TRANSFER CASE.2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY.3 - BOLT.-- This should help.Thanks.Helpmech.

To shift into 4lo you must come to a complete stop, put the transmission in neutral, and step on the brake pedal, then push the 4lo button. To shift out of 4lo, do the same thing. If it's not going into 4hi, check every vacuum line you can find. Everything is vacuum operated. If your vacuum lines are old and crusty or mushy, they may collapse when vacuum is applied. There is one vacuum hose that is hidden under the battery tray that almost always comes loose, and it is the one that locks the front axle. You will need to remove the battery and tray to get to it. If the hose is dried out or stiff, replace it with a new one that is flexible enough to make the sharp bend required to hook up to the actuator. Also check the actuators under the vehicle at the transfer case and front axle.

Did you ever think of having it diagnosed by a qualified repair shop ? Thier are aspects associated with this system you have no clue about. That's the first thing every one goes for , changing the switch . It flashes because codes are stored .
DTC B0768 Service Indicator Circuit High
DTC B2725 ATC Mode Switch Circuit Malfunction
DTC C0300 Rear Speed Sensor Malfunction
DTC C0305 Front Speed Sensor Malfunction
DTC C0308 Motor A/B Circuit Low
DTC C0309 Motor A/B Circuit High
DTC C0310 Motor A/B Circuit Open
DTC C0315 Motor Ground Circuit Open
DTC C0323 T-Case Lock Circuit Low
DTC C0324 T-Case Lock Circuit High
DTC C0327 Encoder Circuit Malfunction
DTC C0357 Park Switch Circuit High
DTC C0362 4LO Discrete Output Circuit High
DTC C0367 Front Axle Control Circuit High
DTC C0374 General System Malfunction
DTC C0376 Front/Rear Shaft Speed Mismatch
DTC C0387 Unable to Perform Shift
DTC C0550 ECU Malfunction
DTC C0611 VIN Information Error
You need a professional scan tool to check for these codes an too view data parameters .
Transfer Case Shift Control Module
The transfer case shift control module uses the VIN information for calculations that are required for the different calibrations used based on axle ratio, transmission, tire size, and engine. The system does not know which calibration to use without this information.
The direct battery supply line (CKT 1640) provides the power to the module and motor circuitry.
Transfer Case Encoder Motor
The transfer case encoder motor consists of a permanent magnet (PM) DC motor and gear reduction assembly. It is located on the left hand side (drivers side) of the transfer case. When activated it turns the sector shaft of the transfer case (clockwise or counter clockwise) to shift the transfer case. The encoder motor is controlled with a pulse width modulated (PWM) circuit within the transfer case shift control module. This circuit consists of a driver on both the Motor A and Motor B circuits. The encoder motor is bi-directional to allow the motor to shift the transfer case from 2HI or 4HI to neutral and 4LO positions.
Transfer Case Encoder
Your best bet ,take it to a qualified repair shop .

Same problem here. Just replaced the vacuum actuator and it still does not work. Could not see any damage to the tubes either. However after I manually move the vacuum actuator I can get it to engage and disengage up to several times but it never lasts

How may buttons for the 4X4 two , three , or four ? Do the lights flash ? Any messages - service four wheel drive system ? Which transfer case does it have ?

Transfer Case - NVG 246-NP8 (Two Speed Automatic)
The transfer case shift control module uses the VIN information for calculations that are required for the different calibrations used based on axle ratio, transmission, tire size, and engine. The system does not know which calibration to use without this information.
Transfer Case Encoder Motor
The transfer case encoder motor consists of a permanent magnet (PM) DC motor and gear reduction assembly. It is located on the left hand side (drivers side) of the transfer case. When activated it turns the sector shaft of the transfer case (clockwise or counter clockwise) to shift the transfer case. The encoder motor is controlled with a pulse width modulated (PWM) circuit within the transfer case shift control module. This circuit consists of a driver on both the Motor Feed A and Motor Feed B circuits. The encoder motor is bi-directional to allow the motor to shift the transfer case from 2HI or 4HI to NEUTRAL and 4LO positions.
Transfer Case Encoder
The encoder is mounted to the transfer case encoder motor assembly and is replaced as an assembly. The encoder converts the sector shaft position (representing a mode or range) into electrical signals inputs to the transfer case shift control module. The module can detect what position the transfer case is in by monitoring the 4 encoder channels (P, A, B, and C). These inputs translates into AUTO 4WD, 2H, 4H, NEUTRAL, and 4L or in transition between gears.
Transfer Case Motor Lock
The transfer case motor lock is used to provide a 2H, 4H, and 4L lock-up feature. When the lock circuit is energized, the transfer case encoder motor is allowed to turn. When the transfer case is placed 2H, 4H, or 4L the motor lock circuit has no power provided to it and the lock is applied. This assures that the transfer case remains in the current gear position. When AUTO 4WD is selected the motor lock remains applied until an adaptive mode (torque is applied to the front propshaft) is required. During an adaptive mode the motor lock circuit is energized and the motor lock is released, enabling the encoder motor to turn and apply torque to the front propshaft.


SERVICE indicator (4WD/AWD) Lamp
The SERVICE indicator (4WD/AWD) lamp is an integral part of the cluster and cannot be serviced separately. This lamp is used to inform the driver of the vehicle of malfunctions within the automatic transfer case (ATC) system. The SERVICE indicator (4WD/AWD) lamp is controlled by the transfer case shift control module via a Class 2 message or by a Sevice Indicator Control Circuit.

The first thing to do before assuming it's a loose wire would be to have it checked for codes , auto zone , advance etc... can not check this codes .
DTC B0768 Service Indicator Circuit High
DTC B2725 ATC Mode Switch Circuit Malfunction
DTC C0300 Rear Speed Sensor Malfunction
DTC C0305 Front Speed Sensor Malfunction
DTC C0308 Motor A/B Circuit Low
DTC C0309 Motor A/B Circuit High
DTC C0310 Motor A/B Circuit Open
DTC C0315 Motor Ground Circuit Open
DTC C0323 T-Case Lock Circuit Low
DTC C0324 T-Case Lock Circuit High
DTC C0327 Encoder Circuit Malfunction
DTC C0357 Park Switch Circuit High
DTC C0362 4LO Discrete Output Circuit High
DTC C0367 Front Axle Control Circuit High
DTC C0374 General System Malfunction
DTC C0376 Front/Rear Shaft Speed Mismatch
DTC C0387 Unable to Perform Shift
DTC C0550 ECU Malfunction
DTC C0611 VIN Information Error

If you know nothing about this , your best bet would be to take it to a qualified repair shop .

something has broke inside the transfer case keeping it from going into any other gear