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4x4 electrical question

2004 f150 4x4, I’ve replaced the actuators, vacuum lines and the vacuum solenoid. Also swapped out the transfer case motor with a known working used one. Checked all of the fuses, still no 4x4. Also, no 4wd indicator on the dash at all. I’ve checked the cw and ccw relays, with a test light, no power at all, Shouldn’t there be some power there to make the transfer case motor switch? I’m stumped, Also from what I’ve read, there’s several fuses for the 4x4 system and mine doesn’t have the #30 fuse, can’t even insert one, is that normal? Needing help.

do you hear a clicking sound in the dash when you move the selector switch from 2H to 4H?

Quote:

Originally Posted by DarrinT04 (Post 6076595)

do you hear a clicking sound in the dash when you move the selector switch from 2H to 4H?

Nothing, no sounds at all.

I don’t have a scan tool, praying it’s not the pcm.

This may seem like a super random question, but have you changed any of your tires since the last time you successfully used your 4x4? The reason I ask is I do know that if there is enough of a difference from one side to the other in tires size, it will not work. It can be as little as 1 brand new tire and the other side being half worn or more.

Wow. Yeah all 4 brand new tires. Bought the truck used knowing 4x4 didn’t work. Still can’t figure it out

Then there are a few things you could check into.
Does your transfer motor engage at all when you turn the selector switch? Whether the actuators engage or not, you should be able to hear the motor click.
You mentioned checking the relays, does that include the ones in the auxiliary fuse box under the hood? It'll be on the inner fender on the drivers side. If not, it would be a good idea to test those relays.
You also said that in your manual there's a listing for a 4x4 fuse that you don't even have a place for in your fuse panel. Is it possible a previous owner replaced the fuse panel with an incorrect model? I know there are several different ones with only minor differences for each year so it would be an easy mistake to make if they weren't paying close enough attention. It might be worth trying to find the exact one Ford lists for your truck and seeing if the numbers match.
Another option would be to test the selector switch itself as well. If you have a multi-meter handy you should be able to just pull it out and test to make sure a signal is being sent at all.

Hopefully one of these help.

All very good points, yeah, no action at the transfer case at all. I was mostly stumped that there’s no power at all to the relays under the hood by the drivers side fender. I was wondering too if someone switched out the whole fuse panel assembly.