2004 F-350 C&C... new front-end noise

Caver Dave

Just holdin' it down here in BFV
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So, was returning from GER Sunday... where I lost (most of the) brakes on it upon reaching Hwy.19 (compounded by losing trailer brakes on Thursday heading up) :poop:
Hit O'Reilly's in Oak Hill to discover pass. rear caliper puking (Sherlocking: it appears the lower caliper pin seized, smoked inner pad, remnants of pad rotated up, allowed pistons to contact smoked rotor until there was clearance for them to pop-out, and resulting in rapid fluid loss), but they had everything (calipers/brackets, pads), so only took a couple of hours to get back to stopping. (will revisit BOTH rotors next month)

Anyway, made the rest of the trip without issue until I got to the Meadows of Dan (15 miles out), when something in the front-end started making a weird chirp/thunk...
Initially thought it was something 6.ohL engine related, but all vitals were good, and nothing amiss under hood.

- Windows down @ 20 mph sounded like passenger side
- Didn't appear to be speed related
- Didn't appear to be suspension related (bumps, etc.)
- Didn't appear to be alignment/steering position related
- Confirmed both hubs unlocked (M-M, not factory)
- Temp checked both unit bearings (both near 100*)
- Temp checked both calipers/rotors (both near 100*) given the previous issue
- Visually checked the shafts/joints to make sure they weren't flopping/slopping (no shiny marks)
- No visible issues w/ suspension components, including newer swaybar links/urethane bushings

Similar sound to trailer suspension popping when turning hard, or a swaybar pop, but happened when going straight.
Was REALLY suspecting a unit bearing seizing, but temps (backsides) discounted that
Began to feel slight feedback thru steering wheel when it happened, but that stopped about a mile from the house and didn't reappear, even when 4LOW to climb hill to shop
 
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Is it floor shift or electric knob 4x4? My old f150 made some wild noises when the vacuum line for the 4x4 on the front passenger let go.
 
Well, after the ride down to the URE Veterans Ride... the noise is still there.

Further indications:
- Sounds like a seal (animal) "barking"... can "feel" it in the steering/floorboard
- Comes and goes very randomly
- Thought it could be a lockout not fully disengaging (maybe is?), but zip-tied the front driveshaft and was still intact when I got back (= driveshaft isn't spinning)
- Guess it could be a unit bearing, but not seeing any signs of heat differential

Any thoughts/ideas appreciated...
 
Those wouldn't (shouldn't) be turning with the hubs unlocked.
 
I'm pretty sure @Lurch830 just dealt with the spindle/stub bearings in his F250.
 
Hmmm, axle ujoint

Those wouldn't (shouldn't) be turning with the hubs unlocked.
That's my thought as well... hubs unlocked and if they found a "halfway in-between" position, would/should spin the driveshaft, which didn't...
I'm pretty sure @Lurch830 just dealt with the spindle/stub bearings in his F250.
IIRC, his were "automagic" hubs... where mine are manual?

Full disclosure, can't figure out WHERE the noise is coming from. Down & back from URE was like fawk it, when it gets hot/dry enough, it'll be obvious... only it wasn't. šŸ˜¬
 
After re-reading his thread... appears his are manual hubs and his description parallels mine šŸ¤”
Super common. Fishing line between the "C" and through the opening between the inner/outer. If it's broken after a drive, either the lock out is no good or the spindle bearing is shot.
 
I averaged 2 years on spindle bearings on my wife's excursion. I even replaced them with Timken and they didn't last any longer. There's just not a good way to grease them and they are so tiny they hold very little grease. I now grease them anytime the rotor comes off just for good measure.
 
After re-reading his thread... appears his are manual hubs and his description parallels mine šŸ¤”
Stock they were the vacuum actuated hubs w/ manual override, I swapped them for manual only hubs thinking that was the problem. Ended up being the spindle bearing that @Jody Treadway called from the start.
 
Stock they were the vacuum actuated hubs w/ manual override, I swapped them for manual only hubs thinking that was the problem. Ended up being the spindle bearing that @Jody Treadway called from the start.
Screenshot_20241117-083931.png
 
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