Front Hub actuator noise

[Expedition04]

Hello, trying to figure out what my fix is, this is what happened

1. Front hub assembly got cooked, replaced
2. Actuator started making noise, thought the diaphragm got cooked
3. Replaced IWE solenoid and actuator, still making washboard noise, drove it lie 20km like this at low speeds 40/60m/hr.
4. Replaced all the vacuum lines with new ones ford kit
5. Replaced vacuum reservoir, popped it with the air hose, trying to clean out the old lines.
6. Did a vacuum test, got readings of 20 in/Hg at the IWE solenoid side, no drop in pressure when engine is revved
7. Tested vacuum at actuator got 19 in/Hg

I'm thinking I cooked the new actuator by driving it?
Any cheap Manuel locking hubs to be had? Big job?
Thanks all!

 

[Expedition04]

Anyone have any ideas, thanks

 

[Skauber]

I think you can find actuators for about 60-70 dollars on RockAuto Parts Catalog , is that within your budget? If it is, you could just disable the solenoid and effectively convert it to a 2wd.