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I'm looking for a cause for a repeating problem. I need to have a lockout replaced. this will be the 4th if it is the right or the third if it's the left. I have the vacume engaged factory hubs. I ALWAYS lock them in manually because I have had the vacume solonoid replaced twice. Is there something that could be causing the hubs to go out? Always the same symptoms when I have a problem. Dash light comes on, grinding in front end when I put it in drive (when stuck) Reverse they will usually grab for a while after they won't in drive. Ford keeps covering the hubs but it is a pain to have a 4x4 except when I really need it.
I've seen hubs stop working, seize up, etc. Even the dials will seize up. But I can't say I've seen recurring cases of hubs breaking in the way you describe before.
I was concerned when I bought the truck about injectors because of the stories I had heared. in the last 4 years I have replaced one injector but the 4x4 has been at issue enough to leave me frusterated. my brothers 02 250 and dads 99 450 have not had these issues and their trucks get alot more abuse than mine. I have had it in to 3 different mechanics (2 of which are dealer) and I'm still having issues. at first I blamed the mechanic, now I'm almost to the point of looking up the Lemon Law.