Been messing with this for a long time now and am honestly about to just give up.
The pedal method and the evoscan method both cause the pump to kick on and occasionally make a "bubble noise" but only a very slight trickle of fluid will come out when I first open the screw and that's it. I can get plenty of fluid out with a vacuum pump on the bleed nipple but it's about 50:50 bubbles to fluid and never comes out clean. I've tried vacuuming with the pump running and nothing really changed. I've tried removing the pressure sensor with the pump running because someone on another forum said air can get locked in there behind it somehow but fluid doesn't even come out when I run it. I've made sure the motor is actually spinning. I've bench tested the solenoid. I've had the pump apart three times and everything looks good and I followed the pump rebuild youtube video to put it back together.

What could possibly be causing this? I'm not averse to opening the pump up again if there is something that can cause an issue like this.

 

i dont mess with acd (i convert them to non acd)... but if it was me, i would pull the line and see if it would flow fluid straight out of the pump... without the line.

 

I don't think the Evoscan method for the ACD quite works properly - I use the pedal method. The Evoscan method works well for AYC, though.
Have you been monitoring your ACD reservoir? If you're getting bubbles, it sounds like either the reservoir is getting too low and sucking air through or you have a leak somewhere in your system. Has the reservoir been getting lower by itself?
In case you're not aware, the system will hold pressure in the accumulator for a small period of time after charging up, so the reservoir level may look like it's fluctuating. I've found it easiest to only check the level at least 30 mins/ 1 hour after driving/testing the car to give it enough time to depressurise again.

 

Dont correlate pump noise with pressure going to ACD. The pumps purpose in life is to fill the accumulator. The accumulator sends pressure to the ACD which is silent.

This is a pressure sensor at the T-case tied to my oil pressure gauge to show that throttle on/off even if you arent hearing something is still sending pressure to the ACD and will still bleed. You will eventually hear the pump kick back on to fill the accumulator.

 

Wow, this is invaluable to me!