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I have an 04 F250 PSD 4x4 with manual hubs. When the hubs are engaged there is a high pitch whine that comes from the front end, noise is louder if the transfer case is also engaged. Whine is also present if the hubs are disengaged and the transfer case is engaged. So far I have pulled both of the hubs out of the truck and replaced the bearings and regreased the assembly. This reduced the noise for a few hundred miles, but now has returned. Any suggestions as to the cause of this whine.
Definitely bearing (or gear) related in the front axle.
It could also be the front output shaft bearing in the transfer case. A good way to isolate it would be to remove the front driveshaft and lock the hubs. If it still makes the noise, it's definitely in the front-end.
Did you check the gear lube? Is it contaminated with water? You might get lucky...
Have you discovered what is causing the whine, I currently have the same issue. I was hoping that new warn hubs would correct it. '03 psd manual 4wd 93,000 miles original ford hubs.
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