Already replied to your other post on the same topic :
http://www.fixya.com/cars/t3532879-2004_ford_f150_supercrew_will_not_engage
Could be a problem with the vac lines to the IWE ( Integrated WheelEnds ), or a problem with the IWE solenoid, or a problem with the ventfrom the IWE.
Start with checking the vac lines, to make sure they are not cracked.
The vac res & IWE solenoid are behind the battery. Here is a diagram of the parts in the IWE vac system
There was a TSB for the 2004-2006 MYs with a bad design IWE solenoid, but this usually was coupled with noise in 2WD.
Start with checking the VAC lines and the vent, next would be to check the IWE solenoid.
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