I have an 04 scab 5.4 with 6" fabtech and 35's..

recently had a strange noise coming from front end and thought exhaust..turns out it is something in my 4x4...

it seems I get this grinding noise while driving mostly when accellerating but the noise goes away if I engage 4x4. The noise started as gradual and only at high rpms..two weeks later, I can't drive down the road without hearing it. I also get a lot of vibration when in 4x4 now(more than usual) and I noticed the 4x4 does not disengage immediately when turned off.

Am I looking at a complete front end re-build? what could have caused this?

 

Front Hubs

 

thanks.. that thread talks about exactly what I have going on..only problem is I replaced the hubs less than six months ago and now I am still having problems...Loud buzzing noise when driving, not wanting to dis-engage from 4hi. Mechanic thinks everything needs replacing..but I think it has something to do with actuator. Can't imagine hubs would need replacing again..Ford did the job last time.

 

Tell the mechanic to check the entire system for leaks. 2004-2008 4X4's are normally always engaged and disengage when you select 4WD.

 

i don't know if this could be the problem but my heat shield was rubbing against the 4x4 shaft (whats connects the front diff to the transmission). I just bent it a bit and all was good