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I swear the suspension is knocking more with the new Bilsteins in than it ever did with the worn stock shocks. Assuming the shocks are all tight (and they are) what else up there can be knocking over bumps? I'm not aware of many rubber bushings up front that can fail and the body to frame bushings look ok.
The real reason for this post is about the front hubs/ 4x4 setup. My front hubs have been all but frozen since I've purchased the vehicle. You can turn the ***** with plyers but that's still a bitch. ESOF works just fine however. Here's the issue:
When turning (and ESOF is switched to 2wd) I'm getting a rhythmic thud from the front end when the wheel is turned very sharply. Would this have something to do with my frozen hubs?
Lastly, when inspecting my ball joints I noticed the axle seals on both sides were hanging free out of their respective bores which begs the question: what are these seals sealing? It doesn't appear that anything has leaked out. This might be a foolish question but I'm not too keen on the logistics of 4wd vehicles.
I think your thud when you turn is your ball joint. As for your frozen hubs just spray a little lube on them and rotate a few times and they should free up. If you get dirt and sand in the space between the hub the plastic on the hub will not move freely. I had to once knck them with a hammer and 2x4 to get loose then sprayed a little lube and worked it in and now they move with a twist of the wrist.
You can do the "ole plier & WD-40" thing to get those hub selectors to turn but that is not a permanent "cure".
Once the hub selector can move freely, it is much easier to get that hub unlocked if it gets stuck again. You basically have to turn the selector and the axle shaft back and forth until one dislodges from the other.
I agree you probably have one hub not unlocking. Try to turn the ujoint/axles by hand behind the wheel id bet one or both may not turn in 2WD. Good chance you may need a new u-joint in the front too if your getting the noise around turns. Id get on top of this cause i had a bronco down for 2 weeks waiting for the correct parts (which ford nor dana made anymore) because the frozen u-joint just destroyed the spindle and hub assembly around turns.
Thanks for the help guys. I suspected it was something with u-joint but don't know enough to be sure and didn't know how to verify. I will take a look and add these parts to my replacement pile regardless of condition.
as for the shocks making more noise, check to make sure the bottom bolt that goes through the shock is tight. I had trouble with bilstein shipping the wrong steel inserts for the bottom of the shock bushing...
Sometimes I think the clamping force of the bottom bolt does more to fasten the shock to the bottom mount than the bolt just going threw the bushing.
Now that's something I have to check for. I never thought of that but it gives me hope, especially if you say you received the wrong sized sleeves. You don't need bolt that thick in there so if that's the problem I could re-sleeve it to a smaller size or drill out the mount (fat chance!).
They had to send new sleeves, that turned out to be too long to ever get in the bottom axle mount. I ground about 2mm off the sleeves and it was a tight fit when sliding them into the bottom mounts, then I snugged the bolt good.
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