Thanks Guys.

I had the decat done prior to the remap. I've had no issues with either the decat or the remap and love the smooth power delivery. I do, however have the dreaded transfer case actuator gear fail. I assume it's a combination of age (2005 with 172 000km), and extra torque, so I need to replace the actuator motor at some point. There was talk on this forum about someone trying to get the nylon gear made up? Not sure what's happened to that. Any ideas?

Search my name, flip that gear. Free fix. Might not be permanent, but been fine for a few months after I did mine.

Thanks Slick - tried that, and discovered someone had beaten me to it :banghead:. So, not really any other option but to replace the unit, unless I can buy the gear separately :( Still, at 172k km, I guess I should be glad she runs so well and relatively trouble free

You can buy the brass gear on ebay. But, I would not do that, as I can't figure out the way to open up that gear plate without damaging it. There are services on ebay that will rebuild it though for around $200+. You can give that a try.

Do you have a link, or do I search for actuator rebuild?