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Notice that recently that when making a tight right turn in a parking lot, I will hear a grumble from the left front. Hmmm. So the other day, checked lug nuts (had new tires installed last month) they were fine. Jacked up left front and found no play in hub or any where else but did notice I couldn't move the hub lock from auto to locked. Checked the other side and it is stuck too. Been a year since I have checked them.
I could rotate the tire while it was on a jack. I started up the motor and engaged the 4x4 into high. Hub locked and now could not rotate the tire, so it appears the EOSF if working. I think it is EOSF, but the vacuum switching seems to work.
Sounds like your needle bearings in the hub are going. Chances are that the stub drive shaft could also be worn pretty bad. According to Ford there is nothing to service in the hubs, which isn't exactly true. You will need new seals for the ESOF to work after you service them, but that minor compared to the expense of replacing the stub drive shaft or the wheel hub. There is a thread on the site showing you how to service them with a bunch of good pictures.
mine did this to. i sprayed penetrating oil around the hub locker itself and worked it back and forth until it freed up.in my case it was dirt and grit that got between the hub and the outer shell of the lock assy. take the tire off and you'll see a big snap ring holding the assy on.remove the snap ring and lightly tap the end of the lock assy to get it to wiggle back and forth until you break the seal of the o-ring thats inside it.once off you can inspect the needle bearings and grease them. as for the growling noise jack it up and turn it all the way to the right and check to see if your new tires are rubbing anything.mine did that to!.
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