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Ok here is what I have-Last year I redid the ball joints on my pickup. I replaced all of the seals etc. When I manually engage the hubs and then disengage the hub, I get a womp womp sound at about 40 mph. Almost like driving over those rumbles strips on the side of the road but more subdued. I have removed the passenger side hub (that is where the sound is from) and reinstalled it and usually that took care of the problem, until the next time I turn the hubs in and then out. Any ideas on what could be causing the issue?
Also, not sure if it is related but when I reinstalled the passenger side axle and then the lockout hub, the hub would not install all the way so I removed one of those washers and it fits fine. Not sure if the axle is in all the way? THoughts?
If these are Ford OEM hubs, they could be sticking 'locked' and allowing the axle to spin at speed. If you have worn parts or bad u-joints, this is where the noise is coming from. You may have two problems: Ford vacuum locking hubs that are failing to unlock, and drivetrain noise due to worn parts. Try running the truck in 2WD (no noise condition) and then manually lock the hubs (using the dial) and see if the noise starts. You need to isolate the noise condition and also the hub lock issue. Consider installing manual hubs if you are tired of not being sure if the OEM hubs unlocked or locked.
I disconnected the vacuum since it messed up the HVAC. Everything is done manually unlocked to locked to unlocked. The hubs were recently disassembled and cleaned