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I recently took my truck out for an off road outing, I didn't go through any deep mud just some mildly rocky terrain. I had to put it in to 4 wheel drive for one hill and I noticed that I had a squeak or squeal coming from my front driver side wheel. It almost sounded like a rock stuck in the brakes, but it only did it while in four wheel drive. I tired it again on just a flat stretch and the same thing happened. The hub was in the Auto position and this is was the first time the four wheel drive has been used since last winter, about February or so. Any ideas? Thanks.
Depending what year your ujoints on the front axles may be greasable. Mine are on my 2019. Had the first two oil changes at two different dealers and then went to a third dealer as the truck was humming in 4wd. They admitted they could hear it on accel or decel on the road but not on the lift. I went and greased the ujoints and almost no noise. So three dealers didn't even know that there was grease zirks........ I told the third dealer the next time I was in and he looked at me like a deer in headlights.....
Just heard this the other day. Tried all these fixes, no joy. Stopped by my favorite suspension shop today and the guy behind the counter said "Oh yeah! Boss had the same thing on his 2020. We tore apart the front end to find the rock we were sure was stuck near the rotor. Turns out this is a known issue with Ford and unrelated to the brakes making noise. Warranty repair." He was busy so I didn't get any more details...
Finally got the truck in for some warranty work - including the squeaking from the front driver side hub when 4X4 was engaged. They tested and determined both front knuckle seals were making noise and replaced them on warranty. However - service writer called and recommended intallation of "Knuckle Seal Severe Duty Brackets" due to ... whatever severe duty is these days in normal Alaska driving ... and $289 in parts later, no Labor because they were already into the project replacing the seals, all is well and quiet.