When all else fails..
J S JS97202 Wireless Chassis Ear - Join the Pricefalls family - Pricefalls.com Online Marketplace & Stores
Get a chassis ear to help identify where the noise is while driving..
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I would just change it... All it takes is some cra* to get into it to make it unreliable.
There are those who check it and say it is fine, but issues still persist until they totally replace it...
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I went to Honolulu Ford, and they sold me the correct 12 point bolt that was required long ago when I lost one because I forgot to put loctite..
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If the 06 is anything like the 04. Then there are 4 speed sensors on each wheel hub, 2 front and 2 back.
https://www.youtube.com/watch?v=B8CE1y5-IX4
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Some times the easiest way to see things is to just jack the truck on four jack stands and let the wheels spin and test each mode 2WD/AWD/4H..
You will see that the front shaft/TC is spinning regardless of which mode you set. The hub actuators will be disengaged only if there is a vacuum...
Actually.. This is slightly true..
The front driveshaft and TC are engaged and spinning in all modes while driving.
By having the TC/DS spinning, this will allow you to switch from 2WD to 4AWD to 4H while driving at speeds like 60+mph. If this was not spinning, just imagine the torque going...
This is a quick fix. 5-10 minutes to replace.. and approx. $40.
Replacing the half shafts will take time to replace, plus make sure you got a torque wrench....
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