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on almost any automatic 4 wheel drive the gears that engage the hub could be stripped out or stuck cause if you know what the gears that engage the wheel than you would know that they are fradgile lookin but that is what im thinkin it is cause that's what happened to my truck so you probally need some manual hubs to make sure they always work or the problem might be that your transmissoin to the front wheels might be jacked up
I don't know Fords that well, but many 4 wheel drive use a small motor basically to engage the 4 wheel drive. These can go bad or become stuck. If you engage the 4 wheel drive with a switch, it is this type. Could be the motor, the switch, fuse.
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