Helping my bud at my house 99 4x4 7.3 six speed 6 position chip warn premium hubs straight exhaust otherwise stock.
We've been trying to get the 4 wheel drive fixed. I am a cummins man and am lost working on this 4wheel drive. When the switch gets turned hubs locked motor running nothing happens. brakes pushed clutch in tried rolling forward back no noise, light, nothing. So we checked fuses relays all good. Pulled the motor off the transfer case bench tested. Works fine. I keep reading about GEM and ESOF and am lost. Plus these parts are expensive. I wish there was a good cheap kit to make it a manual shift.
I was even considering wiring it to manual shift with toggle switches .
I was also thinking about making a plate to match that little **** coming out of the transfer case and making a manual shift type lever.
But before I do anything drastic I just want to check all the electronic crap and figure out what's truly wrong.

 

well the motor could be getting weak to where it doesn't have the power to put it in 4WD but it's fine on the bench. to put a floor shift in, you need the whole T- case and some wiring. but you probably could make up a manual shift for the electric T- case.

 

I have had a problem with mine too, it works sometimes it will engage but then it wont come out of 4x4 and I checked the switch but it has no power, and no fuses blown.

 

Are you getting power to the shift motor when you engage? Also, IIRC you can manually shift the transfer case with a crescent wrench while the shift motor is removed, this would let you know that mechanically the t-case is working, then you would know it was electrical.