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I have been trobleshooting noise and pulled my auto lock hubs off and the one on the driver side is discolered and does not turn smoothly after inspecting it appears that the bearing on the spindle is bad (very loose and sloppy compared to the other side)I think that all the noise was coming from either the hub trying to lock in or the slop in the bearing getting in a bind since this only occurr after hitting bumps , at first I thought it was a wheel bearing but after locking my hubs in it would not do it then if I unlocked the hubs and go 100 or so yards and hit a bump it would start again, is this something that I can replace myself and also thinking of going with the warn manual hubs...thanks for any help timmyp....This is a 1999 250 4x4 made 98 and the spindle is the one that goes thru the wheel hub....
My wifes truck did the same thing . If you hit a bump the left front would make a horrible noise . You should buy a new set of manual lockout hubs . I would go with either Warn or Superwinch .
Are the splines on the axle shaft end torn up? If so, the hub is probably trying to lock in and can't (I'm assuming you have ESOF, otherwise you would know the hubs were not locking b/c they wouldn't turn).
The noise sounds like a perfect description of a shot wheel bearing. When you lock the hubs in, the wheel bearing isn't doing anything (so no noise). When unlocked, the axle rides on the bearing, so tons of noise.
If this is the problem keep your hubs locked until you get the bearing fixed or there will be more damage.
I just did this repair myself (along with ball joints and new hubs) and I found it very "doable" for a non-mechanic with no prior experience.
There is a lot of excellent information on this site, including a full write-up on this topic (in the Excursion forum) including photos.