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I'm having some rubbing/vibration noise coming from the front end when I engage my 4x4. Here is what I have thrown at the issue to TRY to fix it.
1. New U-Joints
2. New Locking Hubs
3. Took grease fitting out of ball joint (thought it was hitting).
The noise is NOT coming from the transfer case at all. It is just a vibration/rubbing sound coming from the front. It does this even if the transfer case is not engaged (4x4 button to 2wd)
the ujoints you changed were the axle shafts or the front drive line ? have you tried raising truck up & spinning the front wheels to isolate noise,is the hubs disengaged while testing.