Oh..that is why.
There is some legit class action lawsuit action here, this amount of corrosion is inexcusable for a 7-year-old jeep. It should be sealed better and probably have a grease zerk on it so you can keep it filled with grease.
As an engineer, I am pretty impressed with the design and concept. For those that are unfamiliar, the motor pushes a plunger that moves a shift fork that unlocks the two sides. The reason the light flashes is that thinner metal shaft is a switch to measure the position of the shift fork. My motor and position switch are operating just fine, I hooked them up to the jeep and watched it cycle a few times.
I cleaned the mechanism, wire wheeled and sanded the parts and it seems to go back together now. As you know, when something rusts it expands, so the lock collar is a little tighter on the splines then I would like. I am going to try to grease it up and reassemble tomorrow.
If this doesn't work, I guess I reprogram my ECU and buy a Currie Antirock?
Chris
