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I have a 2001 F350 with a7.3 power stroke, 6 speed manual with manual t case and hubs. I have a bad grinding noise when in 2 wheel drive. Similar sound as if you are trying to shift t case into 4 wheel drive too slowly. The grinding is constant in 2 wheel drive, but if I shift it into 4 wheel drive, the noise completely goes away. I have been driving around in 4 wheel drive (T case only, manual hubs not locked) for the past 2 days. If I shift back into 2 wheel drive, a constant terrible grinding noise returns. Any thoughts on what could be wrong, and why it goes away in 4 wheel drive?????
Sounds typical of bad needle bearings in your front hubs. When the front driveline is disengaged the half shafts are completely stationary as long as the hubs are unlocked. The ends of the shafts ride in these bearings as the hub spins around the stationary shaft. When in 4WD the shaft and hubs are locked together, so the bearings aren't spinning.
You can lock the front hubs and disengage the T-case to confirm, this is how most people drive until they can get the bearings fixed.
Thanks Tom! I thought it initially sounded like a bad hub when I heard the noise, but was confused when shifting into 4 made it go away. Figured it had to be a problem with the T-case instead. You might have just saved me from unnecessarily taking out my T-case! Thanks!