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My final solution with the switches. I know this won't be everyone's cup of tea, but I like the simple utilitarian look and functionality.

All fixed and mod is working well. Long story short, the drive shaft from the actuator can do a full 360 rotation and can be fitted to the transfer case 180 out. Through testing the voltages at the TCM I was able to establish this and rectify. So can confirm that this works on the 2.5...

No bearing noise to speak of. I have started checking voltages at the TCM pins inline with the workshop manual. The position signals from the actuator are not what they are meant to be. I'm wondering if I have done some damage inside the actuator.

Not really to sure at this point what's happening. With everything back to stock I have a solid lite 4wd light and the VDC light on. Have tried above suggestions but still the same.

I've checked the wiring diagram further. The RE5 transfer case has the same orange and grey colour wires. I didn't disturb any other wires. Looking further into it, there is 4 position switches built into the control motor that report back to the TCU, maybe it doesn't work on the RE5.

I did this mod today on my 2010 facelift 2.5 Mechanically it works, but I get the 4wd light on and flashing low range light that won't clear now.

Awesome, thanks for the pics. Has anyone worked out if there is a feedback signal from the selector that we could read with an Arduino? Could make a little control unit with a touch screen that controls everything automatically. Also, I am the only one who's doing this with a 4cyl? My...

Hi All, Sorry to drag up an old thread. I'd really like to do this mod. All the links to the photos are no longer working.. can anyone share the photos of the wiring and switches? Is the grey and orange wire completely isolated from the computer before the voltage is supplied? Any help...