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I have an '04 F350 CC with a 6.0, and here is my problem!
When I lock in to 4x4 (especially with a load on the back) I get a nasty clicking noise at all speeds, it just clicks faster as I pick up speed. the noise is coming from my Driver's side front wheel. I have yet to try locking my hubs manually, I will give that a shot next time. Does anybody know what this could be???
Sounds like the lock out hub on that side isn't fully engaging. Can you manually lock the hubs??? If so you should. Hard on the system to only have one hub locked in. Try manually locking both hubs in then using 4x4 and see if it still doing it.
When you have some time, let me pull the hub off and see if there is a malfunction at all. It might need some grease and if the hub has to be replaced, you can have my one good one thats sitting in my box at home. See if that fixes the problem.