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I had the same problem, changed to warn manual locking hubs, problem solved....well OK, not solved, just eliminated
the factory vacuum operated hubs are prone to this, they get dirty and stop working....factory parts are expensive, and being made from plastic, will only fail again....I dont mind getting out and locking the manual hubs before off roading or driving in snow....
Does anyone know how to fix the vaccum leak in the hubs. What are the repair parts needed and called. I would like to ask parts store if they have and how much. Or, do they have to be bought at Ford only. Is it hard to change out parts. Appriciate some feedback here.
Usually the problem is the vacuum seal on the backside of the hub. Kind of a pain to fix, but not real hard. With the engine running, place in four wheel drive and pull the vacuum line off the nipple on the front end on both sides. Plug one end and check the other end for vacuum. If there is none than the problem is in a hose or the vacuum pump. Then try to connect each line individually and see if you can tell which side has the leak. This is the one that need the seal replaced. The seal is only about 20-30 bucks at your Ford dealer. You may also want to have them remove and install the new one after you have removed the axle from that side. Then just reinstall.