Well, this has happen to me for the second time today and has become quite embarassing. I kave got my truck stuck in 2wd and go to shift into 4x4, but no 4x4 . I have manually locking hubs on a 94 std cab short bed 4x4. Once a buddies truck starts to pull me out, the 4x4 will kick in after rolling about a foot or so. I know that automatic locking hubs need to roll before engaging, but not mannual. I have never heard of it for manual and this is my 4th ford truck with manual locking hubs and 4x4 and never ran into this. The drive shaft to the front axle is spinning, but the u-joints going into the wheels were not. Is this the hubs needing to be replaced? Greased? hub engagement springs? I dont want to open the front pumpkin unless I need to. Because when I do a limited slip will go in and right now I dont have the money for that. The has been very emabrassing because this truck has a 6 in lift, 35" M/T, 4.56 gears and a detroit locker in the back. I dont enjoy being on the opposite end of a tow strap than what I am used to . Can the Dana 44 TTB handle a selectable locker?

 

If the front driveshaft was spinning but the axleshafts weren't, the problem is in the front axle/differential. I would think you would be hearing some noises comming from there though. Might want to lift up the front axle and do some investigating to find out what is really going on.

You can test the axle by keeping the hubs unlocked, t-case in 2wd and spin the driveshaft and see what you feel and hear and see if the axleshafts are turning or not. Watch the inner axle u-joint too, up by the diff housing. Then try it with the hubs locked. Turn it from the driveshaft and then from each tire. Test the t-case front output: turn the front shaft with the t-case in 4wd, rear tires on the ground, trans in gear, motor off and hubs unlocked. The shaft should stop when it takes up the slack from the t-case. Then try it with the hubs locked, turning from the tires. You should be able to isolate the problem from these tests and go from there.

Assuming this is the half-ton version of the Dana 44, 35" tires and a locker in the front could be asking for trouble if you really 'wheel it, especially if you have some horsepower going to it. I would expect axle u-joints to fail at some point. I wouldn't let that stop me from putting a locker in it though. I would just keep 'axle upgrade' in the back of my mind and make plans for it for the future. If it never breaks, then all the better .