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

Caver Dave

Just holdin' it down here in BFV
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Mar 10, 2005
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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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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. 😬
 
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 🤔
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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