Outer Limits 4x4 Board

hey guys, just wondering if anyone could point me in the right direction, i have an 80 series with the centre difflock pushbutton, the electric motor on the transfer case was not working so we replaced it, not it is working and can hear it engage and dissengage and when its engage you can feel the gears inside binding but it doesnt fully lock, we have the front tailshaft off and can stop it spinning with our hands, anyone hyave any ideas on what the problem could be as im meant to be going fourbying for the weekend and can only work on it on the workshop tonight! please any advice would be awesome cheers mosko

What did you replace exactly? just the motor or entire unit? is there a fork that goes over a dog clutch in there? kinda sounds like the fork isnt in the collar where it is supposed to be.Its been ages since ive worked on cars full time so i dont know exactly how your set up works.

we replaced the electronic motor and the piece thats attached to it that it has 4 bolts that hold it that bolts it on the the side of the transfer case, and has the plug for the push button and a breather hose attached to it the actual piece we replaced only had one small cog on it but inside there was a larger cog with a couple different sizes on it, the transfer case is still attached to the car so we cant really see whats inside,