I'm posting this here because maybe the advanced xterra owners may want to take a stab at this one. On longer highway trips, I get this awfull burning rubber smell from the front left tire.

1-Front brakes replaced 8k ago and look fine.
2-new tires a few months ago with no new alignment. Tires are wearing ok and don't feel hot.
3-Front bearings repacked a month ago. Maybe rotor seals burning up?

It seems to smell more when the free running hubs are locked in but I drive in 2wd at highway speeds and throw it into 4wd high when I need it driving in and out of bad weather.

Could this be from letting the front axle turn at highway speeds eventhough I'm in 2wd most of the time.

You've probably checked this already but there's no scuffing on the inner face of the tire, like it's rubbing on something? And the brake pad on that side isn't dragging?

Might be the burning rubber smell that others have experienced. Check out the "Burning rubber smell" posts in Problems and Annoyances forum.

Thanks-I posted a potential cause under "Problems and Annoyances"