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from what i understand the fronts engage on thier own when setting due to the air pump is off and that lets the plates come back together and engage the 4x4 but when you start the truck they pump back up and pull away.
^ this is correct, everytime you start the truck with it in 2wd vacuum pressure is applied to the IWE's and they unlock, when you shut the truck off vacuum pressure to the IWE's is lost and they lock in. Engaging the 4wd once a month keeps the transfer case shift motor working properly since lack of use will allow corrosion to start forming on the elctrical contacts in the motor.
If thats the case. The pressure air pressure system must be working properly as I have no problems until I engage 4X4. Unless of course it is possable that it wont release the pressure enough to let the 4x4 fully engage.??? Thoughts?
Are you also experiencing vibration with this noise. I have a lifted F-150 as well. When the truck is lifted the front driveline have to get spacers or replaced, most lift kits use spacers; after the install of the spacers you have to have your front driveline balanced or you do hear a grinding noise in four wheel drive. I had to discover this the hard way as you may be. If you dont use fourwheel drive much just have them balanced. If you use it frequently loose the spacers and get new drivelines, fabtech offered some that were designed for the 6" kit I used and have had no problems since i have installed them.
While I agree one hundred percent with you, what's the harm in using it in a straight line? There's no way anything can bind up if he's nit turning, which is all I read saying. NOW,i might very well dre wrong and it wouldn't be the first time
Even in a straight line it will bind, even though front and rear ratios are the same.
Several reasons for this.
The front of the truck weighs different than the rear, even if the tire pressure is exactly the same ...
... deflection at contact patch and resultant "rolling radius" is not the same.
Add in that seldom, if ever, are all 4 tires the same PSI exact, and that unless matched up as a set even when new, tires vary in dimension slightly. Throw in the tires wearing a little different at each corner.
I'll guarantee that even as hard as you try to match it all up ...
... even in a straight line, engage 4wd on dry pavement and you have the drive in a bind within a few feet.
You imagine it as "perfect" when even you know it's not. Those gears don't allow for any imperfections. If it ain't exactly the same, they bind.