I had a similar problem with my 03 F150 Supercrew a couple of weeks ago. My front driveshaft would spin by hand in 2WD, but when I turned the knob to 4WH the driveshat would lock up, but the front wheels would not engage. I found out the shift fork in the transfer case which is made of aluminum and catches on a piece of steel had broke. I believe there is also a shift fork in the front differential that has been known to break on F150s. Your best bet is to take it to a transmission shop, and explain your problem. They should be cheaper than a dealership. Good luck.
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