I have a '96 F-350 with Dana 60 front axle and the torque driven automatic hubs. 4WD worked when I originally bought the truck about 10 years ago. The truck has mostly sat since then although I have put about 20K miles on it over the years. In recent years the hubs would not engage. I took the hubs apart partially and greased them with moly grease before reassembling them. Still hubs do not engage. I just now took them apart completely (removed snap rings and pulled out gears and springs) and cleaned them thoroughly. Everything looked fine (at least to my untrained eye.) I lightly lubricated them with engine oil, reassembled them and reinstalled them. They still do not engage. I did not take the spindle nut off and inspect whatever is under it since I do not have access to a single-tooth spindle nut socket. I figured my problem was the outer part of the hub, not on the inner side. The axles themselves turn in sync with the back wheels under power when I engage 4WD hi or lo and put the truck in drive or reverse with all wheels up on jack stands.

Any suggestions?

 

My 96 F250 had a failed engagement cam on the driver front. I replaced them with the Warn Premium hubs and never looked back. I have to get out and lock the hubs in or unlock them, but replacing the light duty auto hubs with the heavy duty premium hubs seems worth it to me.

 

dito on a 95 f150 never looked back