7i96 pncconf issue?

If only step4/dir4 works and step/dir 0,1,2,3 don't work and they are set up identically in hal
that suggests that the driver chips that connect to step/dir outputs 0,1,2,3 have been
damaged.

You can verify that outputs work by measuring the step+ and step-
and dir+ and dir- outputs when linuxCNC is running and after you have exited LinuxCNC.

With no load, these outputs should be very close to 5V in one state and close to 0V in the other

Is there something I have to do to configure the card with Mesaflash or something?

This would not be a firmware issue

Okay, my multimeter stopped working a few months back so I now have one on order. I should really have one anyways.

Thanks for all the help! I really appreciate it!

I'm not sure I understood your earlier comment on DIR- and STEP- to 7196 ground. Do you have a diagram I could refer to?

The Multimeter didn't take long to get here. Here are the results.

Linuxcnc on, card powered
Step1 =4.38v
Step2 = 4.38v
Step3 = 4.46v
Step4 = 4.47v
Step5 = 5.1v

Lunuxcnc off but card powered
Step1 = 4.38v
Step2 = 4.38v
Step3 4.46v
Step4 = 4.47v
Step5 = 3.9v

So all Axis are the same except Step5 which is the working step. Not sure where to go from here.

Can you check the stepN+ and stepN- to ground?