The serrated inside the diffrential is getting old from the same lock inside the diffrential so there is now way to repair it the only way is the change the lock and the most helpful to get a air locker is much better
SOURCE: 99 nissan pathfinder 4 wheel drive once put into 4 wheel drive popping noise underneath the vehicle
that sounds like a bad universal joint on the transfer case to the front axle. have that checked out
SOURCE: 2004 Ford F-150 extended cab FX4. 4WD problem
The malfunctioning part in my case is what ford calls the "integrated wheel end" which locs the weel hub on the four wheel drive in or out as need. Part is available from Ford and cost about $110.00. I will do this repair myself.
SOURCE: 2004 Ford F-150 extended cab FX4. 4WD problem
Your front hubs are automatic locking hubs, and the gears are hard nylon. These hubs break very easily, therefore causing you to lose your front wheel drive in 4 high, or 4 low. If you replace the hubs with "WARN (name brand) " manual locking hubs, you will never have the issue again. Of course, you will have to get out of the truck and manually lock the hubs, but they are metal gears, and much more durable. I've personally seen the issue several times, and changing the hubs has resolved the issue every time.
SOURCE: When in auto hubs the 4 wheel drive doesn't work
They are operated by vacuum. Check to make sure the vacuum lines are connected and not ripped or anything. If that checks out fine, remove the vacuum line from the hub and apply vacuum to the hub, if the hubs lock then the problem is in the vacuum line or switch.
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