Sounds like something is really messed up in the transfer case. First check that the rear driveshaft is intact and fully connected to the transfer case. If so, the transfer case needs to be repaired/replaced.
In 4hi or 4lo, the front/rear 'differential' is locked, so both front and rear driveshafts should receive power. In AWD, the power is supposed to be divided between front and rear driveshafts, but will allow power to go to the shaft with the least resistance (like non-positraction rear end will allow the tire with the least resistance to get all the power). If the rear output shaft is broken, or the rear drive shaft is broken, all the power is going nowhere in the transfer case.
SOURCE: this is a awd it
have someone inspect the rear diff. ive seen diffs changed to diffrent ones and not change the tag. your problem might be in the back. hope this helps good luck
SOURCE: 2002 merc mountaineer awd wont come out of awd
If the vehicle is made to be a AWD you cannot get it out of AWD unless you take off the front drive shaft
SOURCE: VSA,SH/AWD AND ABS INDICATOR ALL ON
Not positive, but i think its because of the TPMS (tire preasure monitoring system) on the car. If the tpms valve stems were removed and replaced with normal valve stems then the car will register 0 psi in the tires, causing the alarms. Once again im not a mechanic but i think thats what your problem is.
SOURCE: My 2002 2500HD 4x4 front axle not engaging
Try jacking up one side of the front and putting it on a jackstand. Then turn key on(but dont start it) and put it in 4hi. Try to spin the tire in the air. The drive shaft should not turn nor the wheel. If the wheel does then maybe the acuator is not moving in the axle. It worked when you pulled it out but it might be hanging up on something in the axle.
SOURCE: 4wd 4HI and 4LO not working
Check the fuse to the 4x4, if the fuse is good then check the 4x4 electric motor actuator on the transfer case. You should hear it work from 2wd, 4hi to 4low and back to 2wd with the push of the switch. if you don't hear it working then check the wire harness at the actuator motor, look for any damages like corrosion or cracked wire connector clips. If the 4x4 actuator is working on the transfer case, then the front hub 4x4 actuator may have gone bad and that's located on the front differential. It's common for the clip there to corrode and break and is an easy fix with a new collar pin, at worst it's the diaphragm on the vacuum actuator that is located under the battery tray. There is a vacuum switch on the top of the transfer case, driver side but when that fails, your front hub stay's locked in the on position. Good luck and keep me posted and hope it's a simple fuse that has gone bad. You can pick up all these parts at Auto Zone or Parts Source and they will have the step by step instructions for you to get the job done with common tools.
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when tires are on ICE you are in effect, offroad.
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