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Last night, I pulled onto my front yard to unload my groceries and got stuck. I have the auto transfer case and manual locking hubs in my 2004 F-250. I put the transfer switch into 4x4, watched the 4x4 light go on, then proceeded to spin my rear wheels. I then put the switch in 4x4 low, watched the 4x4 low light come one, then proceeded to spin my rear wheels again. I twisted my locking hubs to "lock", and again proceeded to spin my rear wheels.
Does anyone have any insight to why my front wheels were not engaging?
Since the indicator light is working I would guess the actuating switch is also working. So it must be the actuator in the transfer case is burnt up or unplugged check the connector and maybe someone on here can tell you how to test it.
First thing to check is with the front hubs unlocked put the transfer case in 4WD and the transmission in gear/park, get under the truck and try to spin the front driveshaft. It should not spin in either 4hi or 4lo, but should spin easily in 2wd or neutral. If that checks out then your transfer case is shifting fine and the problem is in the frot axle.
With the front of the truck in the air lock the hubs and turn each wheel. Watch through the knuckle and you should see the axle on each side spin as you turn that wheel. If the axle fails to spin when you spin the wheel, you have a bad lockout on that side. If the lockouts seem to be working fine then chock/let down/stop one front wheel from moving (with with both hubs locked) and turn the other wheel with the transfer case in either 2hi or neutral. You should see the front driveshaft turning. If it does not, you have a damaged differential, ring and pinion or spider gears.
On another note, if it were my truck I would either convert the transfer case to a manual shift or swap to a regular transfer case like a NP208 or NP205.