I've got a problem with my truck it's an F-250 and bunch of different years of truck stuck together, Its got a Dana 60 in the front with warn hubs and a 4.10 posi, the truck has a six inch skyjacker lift with 38 inch tsl radials. Now to the problem when the hubs are locked in 2wd i get a clicking in the front end that starts when i take off then stops after 50kh/h and starts again at about 60 now the truck works fine in 2wd with the hubs unlocked and it allso works in 4wd. I've checked everything i can think of, the hubs are new the wheel bearing are tight the axle u-joints are tight the driveshaft is new and all the bearings in the diff feel tight so im stumped. if anyone has any ideas on what could be wrong with my truck it would be greatly appreciated thanks.  

this might sound stupid, but did you grease everything?  

how about the pinion angle? if it's too great, you'll get some noise  

Thats about the only thing left that it could be. is there any way to change that at all?  

i had the same problem on my 94 f150 once i put a 4 inch suspencion lift. it ended up being the axle u-joints. all of the bearings inside of the u-joints grinded down and dissapeared. so when you are under your truck checking to see if anything moves or rattles, there aint nothing thats going rattle till your moving.  

put it in neutral and block the wheels when checking the joints, if they are bound they won't move by hand even if they're bad.  

This is a simple problem. It is either in front hub assembly, inner axle stub or axle shaft ujoints. A tear down and close inspection of them will reveal the cause.  

I have a F250 with alot of rattling and vibration when my hubs are locked in and nothing when  unlocked. I've replaced the hub assembly, u joints and the auto/lock hubs but the it hasn't changed anything. The noise is only on left.  

svend:
I have a F250 with alot of rattling and vibration when my hubs are locked in and nothing when  unlocked. I've replaced the hub assembly, u joints and the auto/lock hubs but the it hasn't changed anything. The noise is only on left.

Did you inspect roller bearing inside spindle for stub shaft and inspect/mic stub shaft too??? It bearing is bad or the stub shaft bearing surface is worn it can "rattle" some at times.  

Thanks alot I will be checking it this weekend  

is the stub shaft supposed to have a little play while, when I took the hubs off the stub shaft seemed loose and the mechanic said it's fine and is replacing the front drive shaft instead.  

The stub shaft rides inside hub and is retained in there by parts of the lockout hub. There is also a thrust washer between back of spindle hub and stub shaft that you might check as when it get worn you can have excessive end play. One more thing, ALWAYS change the seal between stub shaft and spindle hub whenever you have it torn down. Seal is cheap and hard to get to otherwise. I usually replace needle roller bearing inside spindle that stub rides in too by default since it is not pricey either and a pain to get too otherwise. So in a nutshell, when I tear one down, I replace all seals, inner bearings, thrust washers and Ujoints while I am there and be done with it. Parts are cheap considering the time and labor to get to them.