Early 99 F250 7.3 Manual 4WD Extended Cab Short Bed

I need all the experienced help from this wonderful forum again. I am at a loss. I have a slight vibration/medium roar seemingly coming from front. I have tried fixing/replacing several things, with no luck. Need some good new ideas. When I get above 35-40 mph, I can hear a whirling vibration that sounds like tire tread noise (very little tread on tires). When I tap the brakes, seems to make a difference, seems to get louder as I slow down. I can feel it in the clutch and accel. pedals. It is consistent, when I push clutch in and let idle at 45mph, it is still there. Doesn't seem to make a difference when swaying back and forth, maybe a little. When i get below 25-30mph it isn't noticeable.

Here is what i've done so far :
1.Replaced both front wheel bearing assemblies, rotors and brakes
2.Replaced drivers side brake caliper (seemed to be sticking a bit?), will do passenger side tomorrow
3.Serviced both hub locks and verified front axle is not engaged (one was locked for some time, I thought I found issue, but still have vibration)
4. Tightened pitman arm joint, was slightly loose (need to replace)
5. Inspected tie rod ends and other joints, see no noticeable movement, but have not marked them off the culprit list.
6. Tightened output shaft nut, was a little loose
7. Raised rear end off on jack stands, and revved up to 50 mph, and no vibration, so I have excluded u joint and cardan joint, everything points to front end
8. Rotated tires, left front to right rear

What I haven't done :
1. Have a leak in pinion seal, not replaced yet
2. Seems the upper and lower ball joint had the slightest, I mean slightest play in it when lifting the front driver side wheel (I mean less than 16th inch) but could hear it. I haven't done anything with this yet ... may be the problem? Would a tire out of balance wreak this much havoc with this amount of movement?
3. Haven't replaced the pitman arm joint, will but not sure if this can create issue.

Nothing ive done seems to make a difference. Please any ideas to trouble shoot some more. I need a eureka moment, before I thow any more money at it, just about out Sorry for long post

 

Tires with little or no tread, will make all kinds of weird noises. And definitely give you vibration. The other potential noise maker could be front DS being out of balance. But I would put tires on first, regardless if they are the issue, you need them anyway.

 

If the tires have a harmonic, rotate them and see if the noise changes.

 

I've rotated them front DS to right rear, didn't change. I will get new tires next, just to make sure. Thanks.

 

I want to say I read something about a front exhuast hanger making that noise once, but can't find it

 

I found thread about exhaust hanger, seems i would have heard/felt the vibration when I had the rear on jack stands and ran up to 50 mph, but did not. So this narrowed it to front end somewhere. Even after rotating the tires, it is still in front, maybe all my tires are out of balance , I'm going to get new ones today, but am optimistic.

 

Wasn't able to get tires today, must wait till Tuesday. Did replace right caliper, and front shocks. No change. So to recap, I have new wheel bearings, calipers, brakes, shocks, rotors, rotated tires. Front axles are not engaged. Hub locks have been re-greased. Still get a vibration in front end related to speed only, nothing from engine. I'm going to replace tires and get an alignment early this week, but feel like this is not the issue. Any other ideas what it could be ?

 

Pull your front driveshaft and wire tie your axle stubs to make sure nothings moving up front.

Vibration still there, snip a wire tie and drive, still there, snip other and wire tie the other back up.

Eliminate a corner.

Denny

 

I will try that, I zip tied both two days ago, the ties are still on there. I did not remove front drive shaft. I thought since both were tied down it would eliminate them. I also swapped the hub locks. If I had to guess, I would say drivers side front is were it comes from. I feel it in the pedals the most, and when I tap the brakes at 35-40mph it seems to increase the noise.

 

After looking at the work you've done. I would say to my best guess that you are being brake checked. You can drop the front shaft just as a look see, but I would revisit both sides and make sure everything is as it should be.

I have an E99 and I'm twice a year on the slides due to up north michigan weather. I either feel the fronts in the wheel or the rears in my butt.

Dropping the shaft will visibly take it down to your options and is a must do for inspection regardless. 20 min eyeball.

Denny

 

Ya know, I forgot to mention.........you may be looking at replacing your front rubber brake lines to caliper. Go with the stainless braid. They're cheap and after chasing my tail and replacing pads and calipers too often. Shazaam

 

BTW chalk up your shaft and yolks on both ends. (index them so you know it goes in as it came out)

 

I ruled out both of the front brakes, I took both wheels off and compressed the calipers, replaced both wheels and never touched the brakes. Took for a spin at 45-50 mph, still got issue. Had to pump a bit before would slow down

 

Does the front shaft spin when not in 4WD? Also is it ok to remove the locking hubs and drive without them to troubleshoot?

 

Compression won't tell you anything using a tool. If the hoses are compromised it will be a far lower pressure that just makes them drag. They are due, we run the same age and If I had to find a wrinkle in the system, I'd definitely scrub that age spot. Your due. easy quick and cheap. May solve North Korea's problems as well. :')