95 4wd frond end clunking
 

1995 F150 4wd, manual hubs

When I lock in the hubs and have the transfer case in 2wd, I hear a clunking in the front drivetrain when I turn in a circle at full steering wheel lock. The U-joints on the axles are only 2 years old.

I took out the front drive shaft and drove the truck with the hubs locked in and there was no noise.

I figured it had to be the front drive shaft so i replaced the U-joints in the front drive shaft and re-installed it.

When I test drove the truck, the noise was back.

Any ideas what could cause the noise. I am stumped because it seems I have ruled out all of the U-joints.

Thanks

1954F250

do you have a solid front end or twin I beam?

It is the twin traction beam, or whatever Ford called it, not solid.

Check your ball joints i have a 94 150 and it did the same things and it was the ball joints

I think its just because you have the hubs locked in. My '03 SD does the same thing when I have the hubs locked and TC in 2wd. I lock the hubs for use on the jobsite and if I leave the job to get a coffee or something it does the same you mention on dry pavement when the wheel is turned hard, and the BJ's are new. So it may not be a problem at all. Just my .02