yo J,
If the noise is from the auto hubs, yes manual hubs are more relaible.
Inspection and Verification
Automatic Locking Hubs
NOTE: While the vehicle is hoisted, shift into 4-wheel drive from a dead stop and not while rear wheels are rotating in order to avoid slamming the hub locks into the lock position.
Raise vehicle on a hoist so that all wheels are off the ground. Start engine (6007) with vehicle in neutral and transfer case in two-wheel drive. Front wheels should spin freely by hand. Put transfer case in 4WD and put vehicle in gear. Front and rear wheels should rotate together. Put vehicle in neutral and spin front wheels by hand in the forward direction. The front axle and front driveshaft should rotate with the wheels. The additional load of the drivetrain components should be felt once the hub has been engaged. To disengage the hubs, spin the wheels in the opposite direction until an audible click is heard. Spin wheels forward again and they should rotate freely without the axle and driveshaft rotating. Repeat the procedure, only shift into 4-wheel drive and put the vehicle in reverse. This time the hubs should release when the front wheels are spun in the forward direction.
Road Test
When checking front hubs for proper operation, road test the vehicle to make sure the hubs will remain engaged while under load. This is accomplished by engaging 4-wheel drive and taking the vehicle through several turns (both forward and backward) on dry pavement. This will put an additional load on the front wheel at the outside of the turn because it is traveling the greatest distance.
Driving through several turns while traveling in different directions will make sure that both sides of the hub teeth have been tested under load. Hubs that are not sufficiently engaged will pop out when loaded. This is due to the driveline releasing windup and is an indication of hub malfunction.
If slippage is suspected, mark the tire and axle shaft with chalk (after locking the hub) and apply a heavy torque load several times. Then inspect your original indexing marks. If they are no longer aligned, the hubs are not remaining locked when under load. They will have to be replaced.
Should hublocks become submerged in water or mud for a long period of time, water may get past the seals and into the hubs and axle. In this case, all water must be expelled from the system. The axle must be drained by loosening the axle cover and 4x4 Gear Oil F1TZ-19580-A (WSL-M2C191-A) used to refill the axle (F1TZ-19580-A has no equivalent). Disassemble the hubs using procedures in this section and repack the wheel bearings using procedures in this section and dry off the hublocks. Reassemble hubs using procedures in this section. Refer to Section 05-03A or Section 05-03B for replacement of outer axle shaft seals or spindle inner seal and bearing.
by Ford
FRONT AXLE NOISES IN FOUR-WHEEL DRIVE Condition Possible Source Action
- Ratcheting or Buzzing Noise in Front Axle in Two-Wheel Drive, Shortly After Four-Wheel Drive Usage
- Right or left side hublock.
- Popping Sound from Front Axle When in Four-Wheel Drive
- Right or left side hublock.
- REPLACE hublocks as necessary and INSPECT associated camming. REPLACE camming if damaged.
- Ratcheting Noise Upon Self-Engagement of Automatic Hublocks
- High axle motoring torque.
PINPOINT TEST A: NOISE WHILE ENGAGING FOUR-WHEEL DRIVE
A1 VERIFY FRONT AXLE BREAK-IN
- Verify vehicle was driven 250 miles or more in 4-wheel drive.
Has vehicle been driven at least 250 miles in 4-wheel drive?
Yes No GO to
A2. Break in front axle by driving at least 250 miles with hub locked. GO to
A2.
A2 VERIFY LUBRICANT
- Verify front axle differential lubricant is 1.66 liters (56 oz.) of 4x4 Gear Oil F1TZ-19580-A (WSL-M2C191-A).NOTE: There is no equivalent for F1TZ-19580-A (WSL-M2C191-A). Do not substitute any other lubricant.
Is lubricant to specifications?
Yes No GO to
A3. REPLACE differential lubricant with 1.66 liters (56 oz.) of 4x4 Gear Oil F1TZ-19580-A (WSL-M2C191-A). GO to
A3.
A3 VERIFY HUBLOCKS ARE OPERATIONAL
Do hublocks work properly?
Yes No PERFORM road test. GO to
A4. INSPECT right and left side hublocks and REPLACE as necessary. INSPECT associated camming and REPLACE camming if damaged. REPEAT
A3. If hublock is satisfactory, GO to
A4. A4 VERIFY OUTPUT OF TRANSFER CASE CLUTCH
- While performing vehicle road test, push 4x4 button.
Does vehicle shift to 4x4 mode with no buzzing or ratcheting noise?
Yes No Repair is complete. REPLACE clutch coil, housing, lockup collar, lockup fork, return spring and sleeve spring. REPEAT road test. REFER to
Section 07-07A.
