Looking for help from the people on this one. Here's the story in a nutshell.

Information:
1. 2004 Excursion - 6.0 4x4 SOF - 121,000 Miles.
2. Auto locking hubs have been frozen since I bought the truck last year. (I didn't think this had anything to do with my problem since the auto lock was working)
3. 4x4 will shift from 2x4 to 4x4 using the SOF switch without any issue. Everything engages and works just as it should. Auto locking hubs work and the 4x4 engages even though the manual hub adjustment won't turn.
4. 4x4 indicator lights up as expected.

The Problem:
1. 4x4 won't disengage using the SOF. I flip the switch but nothing happen regardless of how long or how far I wait.

What I've done to date.
* Replaced the 4x4 actuator because it would turn one way but not the other.
* The connectors to the actuator itself looked clean and without defect to the eye.
* The new actuator acts exactly the same as the old one so I'm now thinking it has nothing to do with the actuator itself.
* To get it out of 4x4 I've been disconnecting the SOF actuator and manually disengaging the transfer case and then putting the actuator back on.

Not interesting in continuing to through parts at it so any insite or suggestions are greatly appreciated!

 

I will bump your question to SuperDuty, the guys should have an answer for you here.

 

Most likely a bad 4WD shift relay. On the passenger side in the engine compartment you will find 2 or more small relay boxes. You're looking for the relay box with two identical relays and nothing more. It will likely be wrapped in black tape if it's never been opened before.

One relay moves the shift motor from 2WD to 4WD to 4WL. The other relay moves the motor the opposite direction. A common diagnostic practice is to swap the two relays. If one of them is the problem, your ESOF should now shift out of 4WD but not into 4WD. If that happens, first look for corroded pins around the base of the relays and the connection to the box. If everything is clean, or it doesn't start working after it is cleaned up, replace the relays. You can get them from Ford and they're pretty cheap.

 

Going out to check the relays now. Appreciate the information!

 

Thanks for getting this to the right place.

 

No problem as I don't have ESOF in my truck but the guys here know better...

 

Found the relays. Turned out they were on the drivers side. Swapped them just as you suggested and sure enough it will disengage from from 4WD but will not engage into 4WD. I will be ordering a new relay.

Thanks again for the help!

 

Hmm. Yeah, I wonder why I said passenger side. I know they're on the driver side. Good enough though. You found the problem despite my help.

 

Hey man, try applying the break for 10 seconds and turning the SOF switch while foot on the break. This happened to me once and I took it in to ford and this is what they had me do....it worked.

 

I have to say that this post was very helpful to me. I had a similar problem except in my case I could not get the truck into 4WD. Thank you chamberlain and the others who contribute to much to this forum. This has been the defeinitive answer to my troubleshooting Ford truck problems since I joined 7 years back.

 

fordtech08 cured my 2004 F350 4X4-He said put truck in N. Push on brake. Worked like a charm. While in 4x4 L. Cause may have been I put in N. coming down our icy hilly lane and used the brake lightly. Thanks Ford Truck Forum and fordtech08

 

What is the best method to engage the 4x4. ?