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Is there a (large?) issue engaging the manual locking hubs, but not putting the truck into 4WD? Sometimes I'm driving up the canyon and it would be nice to, at the bottom of the canyon (where there is no snow), engage the hubs, but not the 4WD. As I move up the canyon (and into snow country), I would then put it into 4WD. However, I'm not sure what, if any, damage would be caused to have the hubs engaged but no 4WD.
No damage at all, that's the way you are supposed to use it. Some people leave their hubs locked in most of the winter. It will cut fuel mileage though, so I run mine like you mentioned. I can usually predict when I will need 4wd, so I lock them in that day.
You probably don't want to run around on pavement alot with them locked. You're turning the front axle and the knuckles tend to bind on tight corners. Just make wide turns.....
When it's snowing around here, I regularly drive 100 miles with them locked in as I go in and out of the mountains and WV and VA dont know how to plow. As mentioned above, tight turns can be a pain, but other than that no problem. I only lose 1-2 mpg running with them locked in. When you only make 15 it really doesnt matter much anyway...lol
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