Had a similar problem with mine, It was how loose the front drive shaft was, If you can feel any play, i wouldn't recomend driving on the road in 4wd, I can leave my hubs locked in now and I hear no noise at 55, with a newextended front shaft
Check and make sure that shift fork and shift collar are straight. And there's a little needle bearing on the main shaft. The imput shaft rides in there. Make sure it's down in there good.
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