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After helping my parents get their 99 SD into 4wd by manually locking the hubs for them I got to wondering. This is their second set to fail in a few years and they only do maybe 1-2k on the truck a year. So, is it the light use that causes them to not function correctly? Should they put it in 4wd from time to time during the year to try to keep things moving? Lastly, I only spend time here, so I have no idea. Do the other brands have trouble with this or is it just Ford's system that is failure prone?
Anything that doesn't get used will fail with age. I had this happen to an AC system, my previous truck I used 50/2 AC (50mph with 2 windows down). One day I tried my AC, and the compressor seized. I turn my 4wd on at least once a month to spread a little oil over the seals in the diff and x-case. It's not a bad practice to try things from time to time, hopefully you can find a failure before you need it.
I always tried to spray WD40 or the like onto the hub too. So it would penetrate around the twist ****. There is an o-ring inside that area that gets crudded up and makes them stick too. (For manual activiation) The salt from winter roads ultimately did one of my ESOF hub in. I replaced them both with manual Warns.