I have only a few important comments and you will need more to fix your vehicle. Here in the States there were 2 styles of differential in Ford products. One being limited slip or locking style. The other thing to watch is gear ratio. Both differentials must be the same ratio and style for this to work.
If there is a mismatch you will probably only travel a few feet before the transfer case is destroyed when you engage the 4x4.
You will need to get instructions about disassembling the front differential. This can be slightly different depending on if it is a locking style or not. There are Youtube videos for much of this but what I am referring to is USA made vehicles. If you have the same resources where your vehicle is produced then look at your models. If not, see what sister vehicles are made in the States and then look at their videos for repair procedure.
I wish I could help more but am in the dark with a Foreign vehicle.
SOURCE: 2004 Ford F-150 extended cab FX4. 4WD problem
Your front hubs are automatic locking hubs, and the gears are hard nylon. These hubs break very easily, therefore causing you to lose your front wheel drive in 4 high, or 4 low. If you replace the hubs with "WARN (name brand) " manual locking hubs, you will never have the issue again. Of course, you will have to get out of the truck and manually lock the hubs, but they are metal gears, and much more durable. I've personally seen the issue several times, and changing the hubs has resolved the issue every time.
SOURCE: 2005 Ford F150, 5.4L V8, 4x4; The transfer case
Encoder motor located on the transfer case is usually the problem. It is the motor that shifts the transfer case.
Testimonial: "Will look into this and report .Thanks so much"
SOURCE: 2005 ford escape 2x4 with 2.3. Drivers side rear
on alot of breaks are caused from not working evenly the bearing must go in the hub evenly not one side more than the other if you are putting it in evenly then someone may have given you the wrong bearing make sure before you try it again that you do have the right bearing and avoid beaking another one
SOURCE: 2005 f150 front hubs noisey goes away when put in
This is either the IWE ( Integrated Wheel Ends ) solenoid or the vacuum lines / check valve / reservoir for the vacuum system
This is a block diagram of the IWE vacuum system
There is a TSB on the IWE solenoid for the 04 to early build 06 MY F-150s ( right click save as )
http://my.voyager.net/~sscully/file_tsb06_08_15.pdf
This is for the early build where water can get into the IWE vacuum system, causing weak vacuum at the IWE, and the spring is part engaging.
With the engine running, pull the IWE vacuum line ( not the vent line ) and measure vacuum, to make sure it is being applied. This is done with the Mode selector switch in 2WD and the engine must be running ( in park, take safety precautions, chock wheels, parking brake, etc )
Until you can get it fixed, pull the vacuum lines on the IWE ( make sure it is the vacuum line, not the vent line that runs into the engine compartment, and just hangs up there ).
This is so the IWE gear is not being ground down while driving it. The front axle is engaged when you do this, so MPG will suffer, but the truck is just pushing a dead front axle, the transfer case is not turning the front shaft. This is just to try to minimize further damage to the IWE gear ( which can cause a need to replace the IWEs ).
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