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... It sounds like you have one stuckl locked and one stuck open. You're not getting enough vacume to overcome the rust blockage and trigger the hub to engage or disengage, if my theory is correct.
If he has vacuum issues, he should get 4WD with the hubs turned to manual. I agree, it does sound like the driver side is stuck locked, but that can be fixed after he restores 4wd.
F250SD I sent you a pm to answer your location question.
Cool, thanks Keith. I'm learning more and more about this all the time and appreciate all help. I plan to replace my drivetrain fluids, and investigate the hubs asap within the next week.. I'll let you know how it goes!
Thanks for the inquiry Keith.. Right now it's driveable (except in a snowstorm), so waiting until I can find a warm(er) place to work than outside in 20 degree temps... Was hoping to get going on it with a few days of 50 deg. weather a couple of weeks ago, but wifes car needed more attention. I'll keep you posted! Thanks.
I had a similar issue. I removed the hub, which is easy to do, (just squeeze in the snap ring with needle noze pliers and remove the ring, then lightly tap around the hub as you pull it out), and found that there was so much play in my outer axle shaft that it pushed the axle shaft outward farther than it is suposed to go and damaged the hub. Also the stock hub has a rubber boot inside it with a spring and some device that extends and is suposed to retract when manually operating the hub and mine was binding. I couldn't get it apart to fix it but was able to get it into free mode and as long as I don't manually lock it in, it will pull in and release when vacuume operated. I still need to fix the outer axle issue.
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