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I recently bought an '05 Excursion v-10. Love it. I have never had a 4x4 with manual locking hubs though, only shift on the fly. I'm not sure if I have a problem, but here is what I have found... My left front hub says LOCK and FREE, and my right front hub says LOCK and AUTO. When I flip the switch inside to 4H and drive, no sound from front end, but when I engage left hub to LOCK and right hub to LOCK, the front end clicks quite loud and feels like it's binding. If I take either of the hubs out of LOCK, meaning only one locked, there is no clicking. Am I doing something wrong or is that a sign of a problem. Thank you.
They should both be "lock-auto" from the factory. Sounds like someone put a manual Ford hub on one side. If that is the case, i would then get rid of both of them and get a set of warn or mile marker manual hubs and just keep them manual and reliable.
I should have added, if on dry pavement or in a turn with the hubs locked and 4x4 engaged it will clunk and jerk. Only use it in the slippery stuff. It is however OK in the winter to leave the front manual hubs locked and go in and out of 4x4 using the dash switch.