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I was having the same problem of the 4wd not engaging even though the light was solid. After 3 trips to the dealer, they finally opened up the front diff and found metal shavings. Why they didn't diagnose and tear down the truck the first 2 times, I have no idea.

Anyways, they ended up rebuilding the front diff. Seems like a lot of these newer trucks have problems with the 4wd. Makes me wonder how long this will last and if it will always work when I need it.
 
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