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My 02 ford has been having some issues while in 4wd high or low.. When I lock my hubs in you can here a faint thump noise (I think) and when you use the switch to engage four wheel drive, it really makes a loud thumping noise.. It also pulls to the side a bit and is a little harder to control..when in 2wd it is having no issues or noise at all.. Not sure if this could be it or not.. But a whole back I had a small crash and got a new rear axle put on. With the new rear axle on could the front and rear possibly be geared differently? Any ideas help. Thanks all.
Other guys should chime in, but here's my experience...Only having the "thump" present while in 4wd could be the u-joint on the front driveshaft. I had the same issue. Also, potentially a u-joint at the stub axle on either side.
The driveshaft u-joint sees much more stress I believe. Check for play in that u-joint under the truck.
We just blew our front differential because our back tires were new and front tires were not. We run knobbies for snow season and the back tires were 2" bigger circumference than the front, causing the front axle to not be able to keep up with the back, even though both are 3.73 gears. When it was out if 4wd no problems or symptoms. I'm not saying that's your problem. My first thought is a u joint. But if you swapped axles yourself and didn't check the gear ratio, it will definitely be a problem when in 4wd. If a shop did it, your probably fine. You check what axle you have by using your VIN #. Just make sure the gear ratio is the same.
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