CV's Differential, or Transfer?

[Humble]

98 Explorer Sport auto 4-wheel, 4.0 sohc, 97,000 mi

I've reading the forum trying to solve the binding, groaning, moaning, and feels like 4-wheel on tight turns or a wind up toy. This is what I've done:

Replaced sensors on Transfer case
Changed fluids on both differentials and transfer case
replaced front wheel bearings
Jacked up front end, disconnected drive shaft u-joint, turned and spun wheels by hand - smooth spinning except some play in Front Differential
checked out shift motor- it works
disconnected brown wire at transfer case - still disconnected

This weekend I will remove the front drive shaft completely and see if it still binds. I thought with the brown wire disconnected the front wheels won't engage, but still feels like it on tight turns. Some vibration 20-40 mph. Smooth riding at 70.

I hate to pull the front differential if that isn't the problem. Could it be the CV Joints?

It has become personal, between me and the truck. Any ideas?

 

[Rick]

Sounds like CVs to me. With the brown wire mod, you shouldn't have any power being applied to the front wheels. CVs, even while not being driven by the transfer case, sill have to allow the wheels to turn side to side.