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The only problem using 4x4 on dry pavement that may develop is with the front differential/axles. It will have no adverse affect on fuel mileage when the 4x4 is disengaged. Fuel economy will be affected if running in 4x4
I am assuming your mechanic was refering to the front differential and your vehicle is 4x4. If the vehicle is in 4x4 all the time you may notice a " hopping " feeling on corners from the front wheels. Otherwise, the differential should not cause steering issues. What type of problem is the vehicle experiencing that concerns you and would lead your mechanic to assess a bad diff?
Check the oil in the transfer case. If it has lots of metal in it... time for a new one. They aren't the world's strongest.
Another check: Lift the front of the truck, while keeping the rear wheels on the ground. Engage the 4x4 switch (then turn the truck off) crawl under and try to turn the front driveshaft by hand. If it turns and the wheels turn, the transfer case is the problem if it turns but the front wheels don't... front diff issues. Any grinding, crunching etc is also a clue.
This is normal, as most 4x4s do not have a center differential. This will cause the wheels to try and spin at the same speed front to rear and as the front wheels will cover more ground than the rear wheels in a turn, they will drag a little bit. I highly do not recommend using 4 wheel drive on pavement due to this, as it will eventually damage the front differential and will drastically accelerate tire wear.
there was a tsb on loss of 4x4 electrical
A flashing 4X4 lamp and/or a intermittent or loss of power windows, interior lights, rear wiper, or 4x4 system. the loss of 4x4 system was from a module.
The front differential/drive train have no way to slip in four wheel drive. When you make a tight turn the the front wheels travel a different distance than the rear wheels. on snow, ice, mud, or other off road conditions this isn't a problem because there is less friction for the tires and they just slip a little without much indication they are doing so. On dry pavement they cannot slip and cause the front drive train to bind up and eventually hop.
By the way that is not very good for the 4X4 drive train in general so unless you driving a straight line on dry pavement I wouldn't recommend using the 4x4.
In two wheel drive the front drive drain can move independent of the rear drive train so tight turns are not a problem.
SEAL COULD BE LEAKING CAUSE YOU DIDNT LUBRICATE THE SEAL LIPS WITH PETROLEUM JELLY TO HELP THE THE SEAL LIP SEAL OR YOU DAMAGE THE SEAL WHILE DRIVING IT IN.AXLE FLANGE NUTS TORQUE IS 58 FT LBS THE AXLE HUB NUT TORQUE IS 177 FT LBS.
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