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My 05 F-150 (5.4) has an intermittent problem. When I put it into 4 x 4 hi, the light does not always come on. Sometimes it will just flash. Here is a list of everything that has been replaced :
6L3Z-9E441-A VALVE ASY (TWICE)
7L1Z-3C247-A ACTUATOR ASY (THREE TIMES)
4L3Z-1104-AB HUB ASY-WHEE (TWICE)
6L3Z-9H465-B VALVE ASY
Bought the truck used with 29k miles. First winter we had it, I was driving down the street after it sat in the freezing cold all night, it was sluggish in 2wd and sound coming from it sounded as if something were frozen in it. When I would put it in 4 x 4 noise would go away. Then I heard the grinding noise under the drivers floorboard. Same thing, put it in 4 x 4 it quit. They did drain water from the vacuum hoses. Still occasionally hearing the grinding noise under the floorboard and having the valve assy replaced last week, 4 x4 light will not come again. Ford Tech help me. I love my truck but I am ready to trade it in. I've been in 6 times for this problem.
It is your Transfer case motor, I do not see that this part has been replaced yet. That would be the next thing I would replace. Not cheap, new $275, rebuilt ~$150. It is easy to replace though, 1/2 hour repair.
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