Removed the front drive shaft and its driving fine and the turning problem is gone. But what does this mean?

 

t case is in lock mode. both diffs front and rear are open so its like a normal rear wheel drive car.
with front connected all 4 wheels need to turn at different speeds ,WHEN TURNING. in open mode its ok.
think of 4 circles in the snow as you turn a circle. measure them. all different diameters/circumference.

whoever did the fork didnt fully check the system.

 

Whoever rebuilt your t case f'd up. Have it rebuilt by a professional and send the bill to them.

 

oh! did you try shifting to 4hi? you need to be in lock to move in 2wd. in 4 hi you should not move. it would chech the t case. also try 4 lo .
see if t case motor does anything.
at least you know the front diff is ok.

 

I did have it in 4 hi lock when I removed the front drive shaft. It eliminated the problem so I could drive it over to the shop, where it is currently being looked at.

 

i suggested you try all modes to see if the tc is changing. you are skipping stuff that would help you ...
reread my last post if you care.

 

If you removed the front drive shaft and the H3 moves your Tran you case IS in 4HI LOCK. It will not move in 4HI unlock.

As mentioned above earlier. Whomever rebuilt your Tcase F'd up.

 

Update: the mechanic at the other shop took a look at the front axel and transfer case. The problem is internally in the transfer case. He wanted $2,200 to open it and replace whatever is wrong. Since the problem is gone with the front drive shaft removed, I'm going to leave it off and just have it in 2-wheel drive for the time being, already seen an increase in gas mileage. Eventually will have to pay the $2,200 to have it finally fixed since winter is coming up.

 

might get a new one for that money?

fork?,,,fork stuck? encoder out of step?
pull the motor, see if it runs properly?

 

The motor is brand new. But I will pull it and see. What do I have to do exactly for that? Remove the bolts securing it then see if it changes when I press the buttons?