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this could be a few different problems. I suggest taking it to a good transmission shop so they can hook up their computer to see exzactly what the problem is.
It's most likely the "four wheel drive actuator" This is located on the front differential housing. It's cylindrical shaped and has a large hex (about
1-1/4") and two wires coming out of it. Usually they short out and blow the fuse but, I've also seen where they just quit working and sometimes they just get slow to work. The "actuator" has a heating element in it and it warms up, some sort gas, causing it to expand thus engaging the front wheels. In cold weather it may take a minute or so for it to engage, so put in four wheel drive and wait for a bit and see what happens.
First thing is to read out, with a rented scanner, whatever codes the computer is storing instead of just replacing parts. You didn't say whether the transmission is automatic or manual--there are different troubleshooting procedures for each type. Is the shift a floor or column type?
You say 'new' truck, 09? or new used? I have had 3 Fords, 3 w/ manual trans. case, if you go into 4x4 Low range, you must come to a complete stop before shifting the trans. case to 4x4 mode, and I always put trans (automatic) in neutral before slipping into 4x4, it engages smoothly, no grinding. 4x4 high range can be put in while moving, but I would let off the gas pedal, shift to 4x4 high range, then resume accelerating. If there is any grinding going on doing it as above, something isn't right. Check the trans. case fluid level also, to make sure that's not an issue.
Check the solenoid at the front axel. This is a rather common prob. First check that power is at the axel, got power, clean and put it back. Please do not even look at the tranfer case! At worst you may need to replace the axel solenoid! Frankster016
On the axle there is a vacuum Actuator that engages a collar on the axle that engages the four wheel drive if the axel splines are worn or havent been lined up they will get burred and won't allow the collar to line up. You can remove the actuator and see the splines and determine if they need to be fixed.
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