I've searched for a bit and found this one thread but no one ever posted how it was fixed.

https://www.f150online.com/forums/20...500-miles.html

Mine is having the same issue. 06 FX4 Screw 38k. Went to TX from KS day after Christmas and used it a couple times passing in the uncovered snow lane. Was pulling a trailer and didn't feel like having the limited slip kick in going 40-45mph. No issues.

Used it Monday pulling out of a track.

Was backing the trailer in at home today and started spinning. Put it in park. Engaged 4wd and nothing. No lights, no clicks no nothing.

I've checked the 4x4 solenoid fuse. Both PCM 4x4 power fuses.

The 4x4 relays is cartridge fuse. Since I don't have a tester here at home but the connections inside the fuse look fine. I checked it against another cartridge fuse.

I haven't checked the 4x4 ccw fuses under the hood because I have no tester.

Will the lights not come on if the motor on the back of the transfer case is bad or froze up? I figured they would at least flash at me.

Both 4x4 high and low lights come on when you start the trucks, as normal.

Any ideas on what to check next I appreciate.

 

The lights won't come on unless the motor actually shifts. The motor hits a switch when it shifts and that's what actually turns on the light.

Have you tried getting under the truck and tapping the shift motor with a hammer? Sometimes that works as a temporary fix.

 

All back to normal.

It had been sitting outside all day because we got home late and I didn't feel like unhooking the trailer. I just went out in the garage and tried it and it's fine now. Must of been too cold for it. It never really got above low 30s today.

Sounds like this is going to be an issue. And I'm wondering if a new motor will even cure it since it seems to be weather related.

Same thing happened on my 96 FS Bronco when it had auto hubs. I switched those out for Warrens and never had a problem again. Is there a heavy duty motor we can swap out for that isn't as prone to failure in cold weather?

Thanks for the reply. And btw I did try tapping the motor earlier when it wouldn't work.

 

Doubt it's the cold. Mine was working just last week in below zero temps. Including after sitting for several hours cold.

 

My 06 does the same. I tapped the transfer case motor and got it to work. Another thing I do occassionally is when I park it for the night I leave the four wheel drive engaged, seems to stay unstuck longer that way.