rayra
Expedition Leader
I'm pretty confident you'll find the plunger / actuator in the front diff solenoid is all corroded up. Only thing that makes sense to me for it to keep drawing juice until the fuse blows. If the solenoid was dead it wouldnt / shouldn't blow the fuse. And the dash switch is just that. Nothing in there should be causing a draw high enough to melt the fuse.
You might want to check the front diff for water in the diff fluid, too. The vent breather for the front diff ought to be right inboard of the front left shock top (where that ABS harness connector is) right about the top surface of the frame rail, at some point if probably got forded deeper than the vent. Drive it a bit in 4wd to get it frothed up and just pull the fill plug and stick your finger in there and see what the fluid looks like. Before you pull the solenoid.
(silicone) grease up the new sway bar bushings before you clamp the bar back in.
You might want to check the front diff for water in the diff fluid, too. The vent breather for the front diff ought to be right inboard of the front left shock top (where that ABS harness connector is) right about the top surface of the frame rail, at some point if probably got forded deeper than the vent. Drive it a bit in 4wd to get it frothed up and just pull the fill plug and stick your finger in there and see what the fluid looks like. Before you pull the solenoid.
(silicone) grease up the new sway bar bushings before you clamp the bar back in.