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May be the electronic control of the 4x4 has a problem. Remember that when in auto, the 4x4 wil only hook if necessary. Try going on bad roads to see if it works. The differential should probably work in 4x4. The electric motor for the transfer should also be checked. It is important to see if the cubes of every side at the front axe is lubricated.
Generally speaking, no. The computers are pre-programed at the factory for each year and engine-trans combo. Not to say one truck won't run with the other computer, but the check engine light may stay on and performance may suffer.
Your transmission should be in neutral when shift from 4x4 low to high. Also the brake needs to be depressed. If you have done that I would say it is a solenoid in the transfer case or the relay that drives the transfer case solenoid.
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