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I am having issues engaging my 4-wheel drive. The truck drives fine with the hubs engaged or disengaged and the transfer case in 2H. When I put it in 4HI with the hubs locked it feels like the drivers side front is binding. With the hubs disengaged and put in 4HI, I don't hear any noises or binding. With one hub in and other out, it is the same thing. I am only moving it a few feet and slowly to test the different configurations. I am really hoping it is just the hubs that need fixed/replaced rather than the differential. Is there any way to further isolate the problem without disassembling the hole front end. Also I don't really want to buy new hubs and have that not be the problem. Though I guess I can return them. Any help is greatly appreciated!
Put the front end of the truck up on jack stands so the wheels aren't touching the ground. First leave the hubs unlocked, spin the front axle by hand via the axle joints, and see if either side feels abnormally tight. Next do the same thing, but put the truck in 4wd, with it in gear (truck turned off of course) so the drivetrain is locked. Spin the front axle again, this should tell you if its in the diff. Note, you might have to use a screw drive through one of the axle joints to rotate it over. If you have closed front knuckles, disregard all that cause you wont be able to do it.
Next turn the front wheels by hand (hubs unlocked), this should tell you if its in the front wheel bearings, etc. Try it again with hubs locked, should tell you if its related to hubs being locked.
Thats the general method I use to isolate front end trouble, from there on you just have to tear it down.
if your on dry ground it will bind, thats why your not supposed to engage 4wd on pavement.
Its not much different than running 4wd of flat face rocks, which I do often. Sure it will buck and learch a little when turning (esp with lockers f/r), but unless you have a very heavy load where the tires can't break traction, you won't hurt anything by running 4wd on pavement (no reason to, but it won't hurt anything.)
OK, I elevated the front end on jackstands. I spun the drive axles, neither seemed tight. I engaged the transfer case and that locked the front driveline. I was still able to spin both front drive axles without too much effort. I engaged the hubs and there doesn't appear to be any slippage between the hub and the drive axle. I would hold one tire and spin the other. I didn't figure it would do that, but I believe with the limited slip that doesn't sound too far fetched, because it transfers the power to the tire with least resistance. There is a bit of play between the drive shaft and the hubs, but not what I would consider excessive. My guess is that it is the differential. When I engaged the transfer case after doing all of the checks, it felt like someone grabbed the front end and it wasn't going anywhere. There are 160K miles on the truck. It is a Dana 44. Would it be cheaper to have the diff rebuilt or just find a good front axle at the junk yard and swap it out?
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