kcattorney

My biggest pain was releasing the small electrical connection.  The big one was pretty easy - just squeeze the tab on the connector and pull.

But, the small one is a royal PITA.  You must pull out on the tab at the end of the connection, and then pull off the connection.  It's tight up there, so I used a tiny flathead screwdriver to pull out on the tab while I used a bigger screwdriver to put between the end of the connector and the motor casing to pry the connector out.

Here's a pic of the small connector:

On 4/25/2017 at 4:45 PM, Helipilot said:

I appreciate the step by step instructions accompanied with photos. On attempted re-installation, I can't get the splines to line up. The male shaft from the Transfer Case rotates but is spring loaded and returns to a position that doesn't allow alignment with the Stepper Motor side.  The mounting flange of the Stepper Motor doesn't allow for enough twist to align the splines. Aside from taking the stepper motor apart to try to rotate the gear (and running the risk of messing something up), I've exhausted my options and am raising the "white flag".  Does anyone have suggestions or shall I disassemble the Stepper Motor? (2004 Cayenne)

 

Follow up: After searching my toolbox, i located some narrow vice grips and was able to (carefully) clamp them on the Transfer Case shaft, turn the shaft against the spring-load and align the splines to put the Stepper Motor back on. Once the motor was partially on the shaft, I released the vice grips and continued pressing the motor the rest of the way.  (I had to exercise great care not to damage the splines). 

I just used a very large flathead screwdriver to rotate the stepper motor (female slot) with the gear on the transfer case.