I put the truck up on the lift, braced it out with the jack stands and I was able to trace out the problem with my 4 x 4 system to the passenger side hub. No vacuum leaks, no visible problems, and you can hear the mechanism shift when the dash switch is turned... but the wheel does not engage with the half shaft (stub shaft? whatever it is called on our trucks) The drivers side works fine. Turning the manual lock on the passenger hub makes no difference, it still doesn't engage.

So, what could be the problem and how do I fix it?

Thanks,

Keith

 

the hub could be broken, you can take it out and try to clean and lubricate it to see if it fixes it.

 

I will give that a shot. After a google search directed me to other sites, every post about the auto hubs says that if they completely go out Ford replacements are way expensive, and to just replace them with manual locking hubs. I am fine with that, but then when I looked at the recommended hubs (Warn) they only have part numbers for vehicles up to 2004... did our hubs change after 2004 or is there some other reason they don't list parts for newer trucks?

Thanks,

Keith

 

Yeah, 99 to 04 are the same, in 05 they changed the frontend to coil spring and also the hubs are bolt in , the 04s use a C-clip to hold the hubs in. I'm suprised they don't have a listing for newer trucks, after all they are the best trucks made....

 

I pulled the switching mechanizm off of the old auto locking hub, and the internals were all jacked up. It looked like previouse owner didn't know what he was doing, and tried to pull it out and got nervouse and quit after ruining it. At that point I ordered a new one. After the new one came in (next day delivery to my local ford dealership, $200) I used some WD-40 and needle nose vice grips to pull the old unit out, and slide the new unit in... I now have fully functional 4 x 4 system!

When inspecting the hubs and half shafts I did notice what looks like a seal out of place inboard of the hub. I took a picture with my phone, and will post it up to show what I am talking about. I am hoping that it is something that I can just pop back into place, but I don't want to try before consulting the diesel bombers board for advice

Later,

Keith

PS: expect a "auto merged double post" when I figure out how to post pictures

---AutoMerged DoublePost---

And here is the picture of what I was talking about:



Later,

Keith

 

that is really just a dust seal, the oil seal is at the bearing at the center housing, I just used silicone to make it stay in place. That is a good thing to change when you do Ball joints and have everything apart.