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Ok I have a 2006 f250 super duty 5.4. Vacuum for hubs don't work so I manually lock hubs in.
Now with that said I turn switch to 4x4 high to plow then after plowing I switched it to 2wd however the transfer case didn't shift out and the light on instrument cluster stayed light up 4x4.
I have switched relays under hood but no change.
Any ideas of what else it could be would be nice. The only other thing I know to do would be get a new transfer case shift motor
See if putting it into 4lo, then back to 4hi, then back to 2wd does anything. Let it actually engage in each mode (don't just flip the switch quickly).
Having the front hubs locked or unlocked would have no affect on the transfer case engagement.
My son had a similar problem with a 2006 f150 except his would not shift into 4wd. He could make it shift by tapping on the motor, so we replaced the motor. This solved the problem,but I don't know what goes wrong with the motor.
Do you know if it actually is in 4wd? With it set to 2wd, try turning and see if you feel it binding. If it turns smooth, then 4wd isn't engaged even though the 4wd light is on. Then turn the switch to 4hi and turn again. If it binds up, then 4wd did engage.