i had that same problem, in my case it was the selector, i ended up fixing it myself by taking the selector out then taking it apart and re-flowing the solder on the in side with a soldering iron. it took maybe 30 min to do and i haven't had the prob since (8 months)
I disconnected the battery for like 10 minutes, reconnected and the 4wd works now.
2005 Silverado 4x4, 6" RCD lift, M/T Classic locks on BFG KM2's, 4:56 gears, Air-raid CAI, TB spacer, Nelson tuned, Corvette servos, 160 thermostat, Ebay long tube headers, Flowmaster Delta 40, Cognito Motorsports steering upgrades. 2000 Ford Lightning, 2.3 KB, bolt ons, 7.67 on the 1/8th.
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