2003 F150 FX4 with 60,320 miles. With the first snow of the season, it would not go into 4X4. Lights on and clicking heard, but no engagement. Took it to Ford dealer last Friday and was told the front shift fork went to pieces with plastic parts found inside housing.
IS THIS A COMMON PROBLEM, OR A RARE ISSUE????????
As of today repair has not yet been done as part shipment was delayed by a storm.

 

It is pretty common. It seems that if there is a vacuum leak the fork may not completely disengage when it should and the plastic pads will wear sideways and break apart. It is only a $13 part but pulling the axle shaft wouldn't be fun in the snow.

 

Thanks! Estimated cost of repair is $1,125.

 

Holy hell that's a lot for the repair. By myself with no power tools in a driveway it took me three hours, and I took my time, that price is rediculous.

 

Call them back and tell them you want the regular fork, not the solid gold one. That price borders on the bizarre.

 

After 2 weeks in the shop, it's finally fixed. Bill - $1211. Due to our snowstorm last week parts deliveries were delayed and mechanic took several days off for a family emergency. Ford dealer replaced shift fork assembly, took front differential apart and cleaned melted/mashed plastic out, replaced affected axle seals, put it all together, replaced diff fluid and cleaned oil crud from around the drive shaft.
May be a lot of $$$ but we still live in oil country where shop rates start at $100 per hour
I guess, you either make payments, or make repairs.... I hope this is the big one for 2016/17

 

That is a rediculous about of money to replace that but if they basically rebuilt the axle then I wouldn't be too mad.

 

I know this is a old post but just had my shift fork replaced 485.00. Thought that was pretty good.