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I have a 2002 Explorer XLS that won't engage 4x4 when first started in cold weather. This is the 5th winter I've had it and the first time I've had this problem. Last year I had a flashing 4x4 dash indicator, and found that the ground wire had corroded off my transfer case selector motor.
When I hit the 4x4 button now, nothing at all happens. No dash indication, no front wheels engaging, no noises (that I used to hear). After driving for about 15 minutes, the 4x4 works fine and will switch readily. Same problem in 4 high and 4 low.
I've only had this problem this year since the temperature has been below freezing, and I don't have any issues when the temperature is above freezing. What component of the 4x4 system could be affected by cold?
The selenoid may have to force against locked components when cold. This could be an oiling problem. WHen was the last time you changed the transfer case fluid?