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alot of times when engaged on the fly or disengaged on a slope the shift control module on the transfercase can stick. try to re create the terrain when it was engaged and put it in reverse hold the brakes and shift out of fwd let it roll a few feet, stop completely put it in drive. that should pop it out
Hello, This could easily be the CV joints. You were in the vacinity of your problem when you changed the hubs. Although the front differential should be checked for gearlube level, the trans fluid is not going into your differential.
You can siphon out the excess trans fluid. The differential is in a floating mode without being engaged, but the CV joints can easily make noise while not being engaged.
I have had a number of clients with 4x4's swear they had problems with the front end. But many have written back to me and let me know thier problem was the front driveshaft U-joint. This is especially true for noises seeming to come from the passengers front side. As the front U-joint is dead center on the vehicle, it is to the right of the Driver so the driver thinks the noise is coming from the far right side.
I had a prolem with my 1998 Ford Explorer XLT. The 4wd indicator light would randomly start to blink while moving and when I flipped the switch to 4wd hi or low it would engage but easily disengage and the indicator lights would not come on. I was hearing a grinding sound coming from my hubs so I replaced both front hub assemblies and the light stopped blinking and 4wd hi/low works great now. it was about 300 bucks for the hub assemblies and only took me an hour or two to change.
Go to the engine compartment where the relays are located with the fuses. Check or replace the 4 wheel auto engage relay , maybe is not working. Is very clearly mark, I believe is the top right one looking at the bost front front of vehicle to the back. There is a diagram drawing of each relay in the cover, so you can't go wrong.