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I have a 1995 Ford F250 4x4 with manual locking hubs. The noise started as a low growl above 30 mph with the hubs locked and the case in 2 wheel drive. The noise sounds like it coming from the either the front end or transfer case. When I put it in 4 wheel the noise would go away. I recently put a 4 inch lift and 35s on the truck and the noise went from a low growl to a grinding/chattering noise, like gears trying to mesh. In 2 wheel, with hubs locked, the noise is constant. When the truck is in 4 wheel, the noise happens when there is no pressure on the drivetrain. When accelerating or coasting,in 4 wheel drive, the noise goes away. I just had new U-joints put in the front driveline so they are fine. Any ideas on what it could be?
Could pull the front driveshaft and lock the hubs in go for a drive. If it makes noise its in the front end. If not leave the driveshaft out unlock front hubs and engage four wheel drive noise equals transfer case problem no noise leaves driveshaft u joints. Process of elimination
I don't have the resources to tear it apart myself. I was just wondering if someone had something similar happen. I am thinking of buying a rebuilt transfer case but I want to be fairly certain that is the problem before I go and put more money into it.