2004 f250 4x4 manual hubs. No noise when free wheeling with hubs locked in 2wd. pull lever down into 4x4 and get on the gas sounds like the hub is grinding apart pulled hubs apart and can't see any shinny spots where it might be slipping. cleaned the hub locking gears and still the same thing . New wheel bearing hub assy. and drive axle u-joints also. Hub is definitely locked.

 

Sure the noise is coming for the hubs? That makes me think u joints, but could also be locking hub, main axle unitized bearing.

 

I'll check the drive shaft , sound seems to be coming from the axle end area, almost sounds like the engaging sprocket in the hub is not totally engaging but their is no shinny spots on the teeth that lock into the hub

 

Ya, drive shaft u-joints are bad the ones right under the drivers seat, double set, going to replace them al,l just don't get it they aren't used that often , gets locked in summer a couple of times and then the winter, not used all that much

 

changed u-joints, still same growling noise coming from front end only in 4x4 hubs look good no shinny spots on the engagement teeth on the hub assy. changed out hubs from side to side and still same growl as speed or power is added

 

Did ya think to check the fluid level in the front differential? Could be the side carrier bearing in the diff

 

Well found the culprit, everything in the front end was good, it seems their is a ball and socket thing in the driveshaft that went bad and caused the front drive shaft to loose a weight and between those two items was my growling noise and vibration so in the future it will go to driveline shop to get the associated parts replaced because we cannot get the ball and socket thing. In the mean time new front everything and good for another 12 years.

 

Did you replace the CV centering ball assembly when you did the u-joints?

EDIT: NVM - I didn't see that post... DOH!

 

That was the problem part was not listed where I bought the u-joints and it threw a weight

 

You said that 4X4 wasn't used much so you could not understand why the u-joints could be bad. You will find that all the 4X4 parts tend to last longer if they are used often. I leave my front hubs locked in from November until April every winter unless I am on a long (over a 100 miles) road cruise with no bad weather expected and put transfer case into 4-hi with hubs "free" at least once a week for 1/2 mile or so to keep everything free and lubed, u-joints don't like not moving, the grease hardens and then doesn't lube the joint causing premature wear when you do use it also the front differential gets lubed this way as well, I have seen front ring gears that just sat that were badly rust pitted on the top half that wasn't sitting in the lube in the bottom of the diff. By using 4-hi occasionally you coat the gears with a layer of oil to help preserve them.

 

That's what I do every year but last couple of years truck wasn't used much and other things seized like the turbo vanes and know it get used weekly