Front axles issue
 

2011 f150 4x4 limited. So I noticed today that my front axles are still spinning will the truck is in 2wd. I put a vacuum gauge on the line going down to the hubs and it held at 25 no problem and the vacuum port off the solenoid pulled 25.5 at idle. So I put the truck on jack stands, pull the vacuum line and manually give it vacuum and I can hear the actuators unlock. Grab the tires and they spin freely. Reconnect the vacuum line back the the solenoid start the truck and they spin free again. Put the truck back on the ground start it up and put it in drive axles once again are moving in 2wd. I have read a bunch of stuff and tried a bunch, but I'm still having this issue. To add to it there is no grinding noises. Any ideas?

How much vacuum did you give it manually? Did you blow out the lines to see if you had any water inside. I've heard of the hubs staying engaged due to corrosion from water/condensation in the lines. Maybe you happened to give it just enough vacuum manually to break them free. Just a thought.

About 25 on the vacuum gauge. I'm gonna pull the lines and blow them out see it that does anything. I'll report back.

Update
 

Put new actuators in and still the same issue. What I found out is its not the actuators is the transfer case that's staying engaged! I figured I could change the motor on the back of the transfer case, but this model doesn't have an external motor. Any ideas on this issue now??

Do you have the normal 2 speed case with 2H, 4H, and 4L, or do you have the 4A?

I would start with trying to shift the tcase with the switch and see what happens. You can also use Forscan to monitor what mode the tcase is supposed to be in. This might help narrow it down to a switch/electrical issue or a mechanical/shift motor issue.

Mine has 2H, AWD, 4H.

Can you tell if it's AWD or 4H?

It seems to be in AWD. When I put it in 4H I can feel the difference.

Is it possible that the magnetic clutch is stuck engaged? Maybe a relay or something is stuck closed. I'm going to pull the wire connection apart at transfer case and see if that does anything.

Idk, I'm not familiar with how that tcase works.