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Amen to that. Use your 4x4 at least once a month in both ranges. Even if you just go back and fourth in the driveway. The electric shift motors will gum up from not being used. Even if you have a mile or two of straight road, throw it into 4 hi, use 4 low in the driveway or a round in the yard if need be. There's guy's that go for years without using the 4x4 and get mad when it doesn't work, if you don't use it, you can loose it. Also in your case it might of been iced up a little.
Or you can go pop the bucks to convert it to manual and never have that particular again. That's a simple enough change that it can be done in a couple of hours at your convience. The only special tool will be the socket needed to loosen/tighten the lock nuts.
Yeah, thats what I though as well. Then I read that the 4wd system operates through the computer somehow. It you swap to a manual T-case it causes the puter to go nuts. I've been meaning to talk to Doug at bama chips to see if the T-case can be deleted from the computer with a bama engine programer. I never thought the t-case would cause a computer issue, but according to the article I read it does. I don't even remember where I read it or I would post it. However, I know for sure I read it somewhere. I guess we could allways get the computer from an 02, or 03 FX4 level II that had the manual T-case. Ford still sells them , I checked as I was serious about doing this swap and still am. I just need to gather up my info and parts.