I have a 04 f150 fx4 and recently I discovered the 4wd kept slipping out while I was stuck. Turns out I broke the locking hub in the front left wheel while trying to get it out. Before I got it fixed I heard a thumping noise from the front left wheel when turning at just around 45 degree angle. When I went to get it fixed they called me saying the locking hub was broken so I figured the sound was coming from that. But no it isn't it is still making a noise and I have no idea what it could be. Everything is fixed and I trust the guy who fixed it. My whole family has known him for a very long time.

 

Does it still make the noise in 4wd? Did your mechanic test the actuator since the hub was broken? It could even be your cv axle tring to bind. If you were giving it hell trying to get out of a rut, you could have messed up the axle. I have a used motorcraft one with less than 5000 miles Ill sell ya. Not a thing wrong with it. I was having an issue with my drivers side and went to throwing a new axle on it. After I did all yhe work, it turned out to be the actuator. I didnt feel like taking the new one back off so the motorcraft one has been sittin at the shop.

 

No it doesn't make the noise in 4wd. It makes it in normal conditions going around a turn. It makes a thump noise like every rotation of the the wheel when turning at a 45 degree angle.