re: F150 4WD Issue - Update and new Question in OP

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Have you put a code reader on it yet?

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No, I haven't. I'll try to get that done this afternoon.

I know the transfer case shifts by the actuator motor. But, I think I've read something about the hubs being vacuum actuated? I haven't noticed any chatter from anywhere. It's fine until I try to shift it.

Yes, I do use it fairly often during the fall/winter months.