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I had the same problem. The hubs would always "click" when the truck was in 2WD with the hubs locked. I have the Warm premiums. I thought maybe I needed the spindle nut conversion kit because my truck may have had the autocrap hubs originally. I took both hubs apart, checked them out and everything seemed fine, but still the clicking. It would clunk around and make awful noises in 4WD. After that, we found that the front driveshaft u-joints were shot. Once they were replaced, the hubs have worked great eversince. There is still quite a bit of fron drivetrain noise however. I hope that in some way my rambling can help you.
that sounds similiar to my problem except mine still engages in 4wd fine with the noises, its in the shop now so im usre theyll figure it out,loL! ill post back what the issue with it was
Ford hubs may be the cheaper way to go. They are basically the same as warns, but are red with FORD on them instead of black and WARN on the turn dials... just my .02
I got my Warn premium hubs at advance auto for $89, i thought that was a really good price for quality hubs. I am slightly disappointed with them though. Salt got inside one of them and really corroded inside the cap. The salt got in through the dial for some reason. This problem was corrected and now they work fine. They are not as easy to turn as the regular hubs though. I think the premiums are the best looking.
guy at the shop i dropped it off to said the angle of my driveshaft is off a lil to much and thats why its making a noise?? .... ive owned this truck for like 2yrs almost, and only had it in 4wd a handful of times and honestly its always been a lil noisey, think its a lil more noisey now after all the new stuff up front but ive always had superswampers on it too and they were noisey so they prolly drownded out the sound im hearing now with the quieter 40's, its got a 6" susp and its got a leaf added to it, 3" body. ill have to post a pic of my setup to see but he wants to cut the drive shaft and add another ujoint basically, or CVD to it. what do you guys think of this?
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