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I have a 2003,6.0,350 super duty 4x4.I have the switch on the dash for 4x4 but it wont go into 4x4 high or low when i turn the switch.I had it put on a computer and it said the switch was telling it to go to 4 high and 4 low.I had a mechanic look at it and he pulled the motor on the transfer case and said that was working.I also had a problem of when i started the trk and put in reverse the trk wouldn't move.I put it in park and it started grinding like if i was moving and put it in park. I shut the motor off and started again and still wouldn't move in reverse or forward and it would grind when i put in park.I did this about five times and then i started the trk and put in reverse and heard a loud clunking sound that sounded like the front differencel and the trk went into reverse and forward just fine.This has happend twice,the next time was three starts later.It has been about ten days since the last time it happened.The 4x4 light on the dash stays on switch is in 2 high
The transfer case shift motor on this vehicle uses a shift encoder. The shift encoder is a multi contact plate that tells the module what position the motor is in. If the shift encoder is intermittently giving data that is not coherent (not a proper reading for any known transfer case position), the module will not shift the transfer case, or it may end up in an incorrect position like the neutral position you found it to be in before it clunked into gear. I think it is likely that the shift encoder is defective, requiring t case motor replacement. However, to properly diagnose it, it needs to be reconnected to the scan tool and the plate contact on the encoder read and compared to the proper readings. You can also have shift solenoids that are defective, or a GEM module that has a defect. The most common failure is the shift motor. Steve
Ford Technician
Ford Senior Master Technician, ASE Master Technician 33 years experience