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Something you might find handy is a signal tracer (about $40) which can be used in the home or auto. It has 2 components and creates a signal into the wire which allows you to follow that signal down the wire to find the break. (Lowes, Home Depot) Has connectors for fuse panel holders.
You do not want to directly jump 12 volts into the shift motor. The voltage the shift motor receives determines the length the solenoid extends to give you different functions. The 4x4 selector changes the voltage for each function. ONE thing you can check is the light bulb for the 4x4 selector knob. There have been reports on this site that a burned out light bulb can change the voltage for the 4x4 selector. Myself, it seems strange because the lightbulb is off until the headlights, etc. are turned on, so it would make no sense to effect the 4x4 selector during daylight.
Since you have a duplicate shift solenoid you may be able to plug in the wiring harness and ground the extra shift solenoid to aid in diagnosing the problem.
You could loosen up the fuse box holding these particular wires and check them on their backsides. Also check to see if there is a shift selector relay.
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.
This is for 4x4 shifter on the floor.
In the front of the truck on the axle there's a plastic cover with 2 10mm bolts remove it and spray down the shifting actuator it operates on vacuum. You might have to pull it in four wheel and check to see if the vacuum pod is engaging the shift lever on the axle. Then again you might have to replace it very easy to do. But I would spray it down with some WD-40 it should work.
I also have a 97 F-150 4x4. If that was my truck I first would change the fluid in the transfer case. See if that helps loosen it up. It is possible that it has the wrong fluid in it.
does it stay in gear,when you manually shift it ? The electric 4x4 motor gets dirt and water inside the motor.if it works ok shifting it,try replacing the motor.
if this is shift on the fly 4x4(electronic shift),check all fuses first.Try lightly tapping on the 4x4 electric motor on the transfer case,if it changes,replace the 4x4 motor.Water and dirt get in the 4x4 motor,causing it to stick.
I'll assume that you have a 4x4 switch on the dash; check the shifting motor and plug on the transfer case, or the digital output from the GEM module which controls the 4x4 operation.
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