Looks like my attack plan is going to be to first change the gear in the servo motor. As you guys have already indicated, its the cheapest way to go for now. Hopefully, that'll be the cure but if not, I'll move to next part. I'll let you know what happens once I get the gear installed.

One question I forgot to ask. Once the gear is swapped out and the motor reinstalled, does the truck need any software coding, resetting or recalibration?

Thanks

From what I've read, there are two schools of thought on this.
The instructions from various people "in the know" is that you don't need to have anything recoded provided you don't disengage the brushes/feedback sensor when dismantling the servo motor, basically they say to keep the black plastic piece that houses the brushes and fedback sensor with the motor armature and housing.
To me this seems to be pointless because the motor will turn when the new gear is fitted and you're unlikely to get the gear back engaged in the transfer case with the motor armature in exactly the same position.
I suspect it's mentioned just to make things easier so you don't have to worry about getting the motor brushes back in place.

I didn't bother getting mine recalibrated after fitting the new gear and so far there has been no adverse effects, and it appears to functioning properly.
I suspect there must be some type of automatic recalibration process the servo motor goes through when you turn the engine on/off otherwise it would not be able cope with wear and tear within the transfer case clutch.

Hi Everyone - I know it's been a while and it's time for an update. My truck has been still randomly throwing the "trifecta of lights" plus my radio would shut off and turn back on. Sometimes it wouldn't happen for a week and sometimes it would happen 5 times a day. Anyway, I finally ordered an alternator, a brand new Valeo (taking a chance at that starting point rather than the gear or the abs module). I finally had it installed today.

Hopefully, that'll cure the trifecta of lights. I'll be driving and update the posting to let you know what happens. Fingers crossed!!!!!!

Will be interested to see if that corrects the problem. Since it is intermittent doesn't seem like an alternator issue but hopefully it is. Good luck!

Update - it's been a week now with the new alternator. So far so good! No trifecta of lights and no radio shut off/on. Looks like the new alternator solved the issue.

Wait have you tried flipping the gear. Search for my threads. I fixed my trifecta by removing X drive servo motor. Unscrew electric actuator motor off housing, look through shaft and you will see gear. I bet your teeth are shaved. This is really common on our cars. Fix is free to try. I am years later still on flipped gear. So yea free just make sure you flip that shit 180. Mark it up before you disconnect actator from housing. Oh and don't worry. I accidentally took it apart hard core. I put it all back together and no coding or anything. It has just been working no issues.

Oh. Lol missed the alternator fixing it post. Good job.

Last update w/ the new alternator - still no trifecta of lights and/or radio shut off/turn on since my last posting. Looks like the new alternator solved the problem. I know many of us think that the actuator gear is the most likely cause but I guess in my case the radio shutting off and turning off is a clue that the issue is electrical - thus, the alternator.

Thanks to everyone who helped!

^Great job! Please mark SOLVED in the thread title and update the first post to let us know what the resolution was