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The auto matic lockouts on my91 f150(not push button) appear to not be disengaging. The only way i can tell this by myself (no one is around to move truck while i look undrneath at the axle shafts and drive shaft) is that when i make a hard turn i hear a clicking noise. The truck steers easily, and doesn't act like it does when you have the hubs engaged,but I noticed that the truck will shift into four wheel when going down the highway even after i have backed up the 20 ft in 2 wheel drive. I was wondering if it is possible that a hub or both are just partially engaged and that is why i only here the noise when i turn and extra torque is put on the wheels. one thing about the auto hubs that i have never understood is that according to my manual if you havea push button transfer case you never have to stop to let your hubs engage.Idont understand the difference when the hubs are the same , and only the transfer cases are different.
any help appreciated
The Borg Warner 1356 T-case for pushbutton 4WD has an electric clutch inside to spin the front drive shaft up to speed with some grace. Then the clutch shuts off, and its a mechanical connection. I think that's to prevent a big "bang" on engagement of the front drive, because it was all sitting there stopped with auto hubs. Maybe the lever version of the T-case doesn't have that clutch.
About your hubs, try putting a piece of white tape or something on each axle shaft, then pull ahead about a half-wheel rotation in 2WD, then check where the tapes are. Could also jack up one front wheel at a time, and see if you can spin tire by hand easily, with only brake rotor drag, if hub is unlocked.
If one hub is staying locked in 2WD, that wheel drives that shaft into differential, the other axle shaft tends to rotate backward, and the unlocked hub on the other side tries to lock against the shaft rotating the wrong direction, but it can't. This gives the characteristic ratcheting sound at low speed.
I would highly suggest getting yourself a pair of Warn manual locking hubs(and the kit to convert from auto to manual). It really is not that bad to get out and lock them in. If you know you might need 4x, you can lock the hubs in advance then shift to 4x when needed.(like driving to work on a snowy day).
Just my 2cents.
Good Luck
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