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I'm throwing this question over here since it has the same drivetrain and there are twice as many people...I've got a 03 Excursion 4x4 with 47k miles. I drove about two hundred miles yesterday and after the trip I made a u turn and herd only what I can describe as a popping sound that could be felt through the wheel. The four wheel drive was not engaged. I put it in four wheel drive, drove for about a quarter mile then took it back out. Noise gone. Any ideas? I also notice a few months ago when I parked on the ice covered driveway in two wheel drive, the truck started sliding backwards, but the front wheels did not spin freely. I'm thinking that the problem my be a bad vacuum solenoid causing the front drivetrain to engage without the transfer case, or maybe a sticky hub? Any input is appreciated.
Congradulations, you're now a member of the "Hub Club". One of your front hubs was locked up when you turned a corner and the popping you heard/felt was U-joint bind. You need to pull your front hubs and clean them. Do a search, it's a popular subject on the Super Duty board. I eventually dumped my automatic hubs and went with MileMarker manual hubs because they're cheaper and stronger thatn anything else available.
How can the hub stick in the locked position if i havent engaged four wheel drive. I didn't have any problems before the trip then afterwards the problem started, at no time was the four wheel drive engaged. Thanks for speedy response.