Noise hubs unlocked...no noise locked in 2wd

[bustertoyota]

82 4x4 pickup.

Have a noise that is a cross between grinding and rattling when
coasting
driving under power
2wd with hubs in 4x2
steer hard to the right when hard turning left to right back and forth

Was not felt through either shifter or through pedals.

Had recently rebuilt the knuckles so I tore into one side and found the thrust washer had a spot rubbed into it from the bearing cup rolling against it. Redid preload and buttoned it back up. While I was dinking around I locked the passenger side hub. Forgot about it and drove to work the next day...no noise. Went to drive to work next day and remembered I had locked the hub while working drivers side bearing and unlocked it. Started out down the road and my grinding noise was back...did not link hubs locked\unlocked to noise till tonight.

Tonight I come home, lock hubs and go for a test drive. No noise. During test drive I went back and forth between 4x4 and 4x2 and got consistent results. Noise goes away when locked in 4x4 running in 2wd.

Thought I could toss this out there and by the time I wake up maybe someone has some time saver suggestions.

 

[bustertoyota]

Front is blocked up. Rolling drivers side front wheel by hand in 4x2 produces the noise.

Still not sure what it is. 2 year old is not going to let me get further on this today.

 

[bustertoyota]

Ferrous material in locking hub flange. No wear on drive shaft.

Looks like the hub is worn out. It is a superwinch and I cannot get new parts for it.

When I shake the hub body the splined insert rattles. That is how much play is in it.

 

[ferg]

Get some genuine Aisin Toyota hubs. Problem solved.

 

[bustertoyota]

I am actually in the process of trying to sell\trade the truck. Wife and I gave it long thought and we would just be throwing money at it. I think the worn hub is going to be a turnover item. I am going to replace trucks daily driver function with my FJ60.

Good lesson though. When buying an older 4x4 make sure these types of components have not been replaced with lesser quality parts. That would be a price negotiating item in future.

This image shows what looks like galling just above that machined looking ring in the surface.