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Try taking your t/c motor off and using a 12v power source on the 2 prong side of motor to cycle it back in forth and the make sure you have it back in same position as when you remove it and put it back on. This will let you know that the motor function of it is good .not to say that the other plug which controls position could be bad, mine was stuck in 4wd and this is wht I did and it started working again, I think from not using them very much they get sticky on either motor or positioning circuit, hope this helps and try to engage your 4wd once a week just to keep things moving.
PS-the Tcase motor is turned on by the GEM module Fords version of a body control module, usally what happens is the contact plate which the cover can be taken off and cleaned gets crap in it causing the interm operation of the TCCM.
Last edited by mofasta; 01-02-2011 at 07:09 AM.