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Strange Noises from rear

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Old 06-13-2013, 07:50 AM
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Everything underneath looks good - last night I took it to a hill where I could pick up speed going up. I put truck in 4wd and went up the hill and not a single sound. Turned around and did it again in 2wd and the noise happened right away. Repeated the whole cycle again and it still happened in 2wd but not in 4wd.

I replaced the actuators thinking they were my main problem but that didnt fix it so it seems it is either the 4wd solenoid or a leak in the vacuum hose going from the solenoid to the actuators. (Might just pick up both parts today)

I thought for sure and was hoping it was the solenoid easy fix and part on $29 but my mechanic at the firehouse seems to think it is ok because we took vac hoses off of it and it was pulling air in and as soon as I switched truck into 4wd the vacuum stopped. But the other odd thing is my battery light on my console came on a little while back and went on and off for a day or so. Took it to have battery checked and alternator.... passed all tests.

Then the battery light started coming on every day (sometimes going on and off when driving)so far I have had alternator and battery checked by 3 different people with 3 different meters and they all say everything is fine. I am wondering if the solenoid is going bad and would throw a battery indicator light at me.... just find it odd a check engine light would not come one.
Old 06-13-2013, 11:10 AM
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Originally Posted by captainron19
Everything underneath looks good - last night I took it to a hill where I could pick up speed going up. I put truck in 4wd and went up the hill and not a single sound. Turned around and did it again in 2wd and the noise happened right away. Repeated the whole cycle again and it still happened in 2wd but not in 4wd.

I replaced the actuators thinking they were my main problem but that didnt fix it so it seems it is either the 4wd solenoid or a leak in the vacuum hose going from the solenoid to the actuators. (Might just pick up both parts today)

I thought for sure and was hoping it was the solenoid easy fix and part on $29 but my mechanic at the firehouse seems to think it is ok because we took vac hoses off of it and it was pulling air in and as soon as I switched truck into 4wd the vacuum stopped. But the other odd thing is my battery light on my console came on a little while back and went on and off for a day or so. Took it to have battery checked and alternator.... passed all tests.

Then the battery light started coming on every day (sometimes going on and off when driving)so far I have had alternator and battery checked by 3 different people with 3 different meters and they all say everything is fine. I am wondering if the solenoid is going bad and would throw a battery indicator light at me.... just find it odd a check engine light would not come one.
The regulators on our alternators are prone to go out. I just replaced mine with a brand new one. When I took the old one to have it rebuilt, he advised me that he had rebuilt a ton of Ford's alternators due to the regulator shorting out and burning up.
Old 06-15-2013, 07:52 PM
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Originally Posted by alsatropine
The regulators on our alternators are prone to go out. I just replaced mine with a brand new one. When I took the old one to have it rebuilt, he advised me that he had rebuilt a ton of Ford's alternators due to the regulator shorting out and burning up.
Is there any way to trouble shoot that and see if that is the problem?

On a good note..... replaced both the solenoid and the entire vac hose assembly today for the 4wd actuator system (IWE) and the noise is gone !
Old 06-16-2013, 01:21 PM
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That's great news.. Glad you got it figured out.. Sorry that I'm not much help with electrical.
Old 08-01-2013, 08:58 AM
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If anyone is still watching this thread. ....

2005 Ford F150 FX4 8Cyl



As stated earlier the noise seemed to happen mostly when going uphill when the truck was under a load. It would stop as soon as I let off the accelerator. After some trouble shooting found the problem definitely to be something with the 4wd accuators losing a vacuum and the 4wd attempting to engage..... apparently a common issue. I also did some troubleshooting by driving up a hill where the sound would always happen but in 4wd and the sound did not happen at all.

The first step i took was to replace the actuators themselves but it did not fix the problem (figures I took the most expensive route first) Next I replaced the solenoid for the system along with the vacuum hose assembly going to both hubs. After doing that the noise stopped and truck has been quiet for over a month.

Yesterday I towed my boat for the first time since making repairs and the noise returned. It only happened when I was driving on the highway and kept happening when ever going up a steep incline. After i unhooked the boat I drove the truck quite a bit including going up more hills and the noise did not happen at all.

As far as I know I have replaced all parts of the 4wd accuator system and it did seem to work because no more noise but it is still happening when under a heavy load (towing boat).

Anyone have any options I can try now ?
Old 08-01-2013, 07:11 PM
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What about the clutch packs in the rear?
Old 08-01-2013, 07:34 PM
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Originally Posted by 09_XLT
What about the clutch packs in the rear?

Didnt give them any thought..... sound is definitely coming from front hubs and it is definitely something with the 4wd actuators because sound stops as soon as I let off accelerator

Since I replaced everything with the 4wd actuator system I think the only thing left is the hoseline going from the solenoid to the manifold (may have a small leak) which would explain the problem happening only when I tow the boat now
Old 08-02-2013, 09:33 AM
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Hey captain Ron,

Ok, I actually had the exact same problem last week on my 06 f140 4x4.. It only happened when I was towing. There are 3 small check valves on the vacuum system. They are designed to help hold vacuum on the hubs because the vacuum fluctuates when you accelerate/ brake/ etc... If you trace the lines coming from the brake booster, it looks like a small plastic fitting in the middle of the line. The first one is about a foot from the brake booster. the second and third ones are close to the solenoid. MAKE SURE YOU REMEMBER WHAT WAY THEY COME OUT. you can remove them and try to blow through them. it should blow through one direction and not the other direction... Mine were 1/2 white and 1/2 black. I checked through my entire system and after doing some research, I figured out what they were for. It was a 5$ fix and the noise disappeared. And even if you already replaced all of the vac lines, the check valves can affect you.. Also, did you check the vacuum reservoir or the tubing going it it? It's located behind the battery box?

Let me know

Ps, what FD are you with? I'm a current candidate for the San Antonio FD
Old 08-02-2013, 05:14 PM
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Originally Posted by BensKingRanch
Hey captain Ron,

Ok, I actually had the exact same problem last week on my 06 f140 4x4.. It only happened when I was towing. There are 3 small check valves on the vacuum system. They are designed to help hold vacuum on the hubs because the vacuum fluctuates when you accelerate/ brake/ etc... If you trace the lines coming from the brake booster, it looks like a small plastic fitting in the middle of the line. The first one is about a foot from the brake booster. the second and third ones are close to the solenoid. MAKE SURE YOU REMEMBER WHAT WAY THEY COME OUT. you can remove them and try to blow through them. it should blow through one direction and not the other direction... Mine were 1/2 white and 1/2 black. I checked through my entire system and after doing some research, I figured out what they were for. It was a 5$ fix and the noise disappeared. And even if you already replaced all of the vac lines, the check valves can affect you.. Also, did you check the vacuum reservoir or the tubing going it it? It's located behind the battery box?

Let me know

Ps, what FD are you with? I'm a current candidate for the San Antonio FD

Thanks.... I actually ordered a new vac resovoir and 2 replacement check valves from Ford this morning.

I work for Hamilton Twp Fire Department in NJ (About midway between Philadelphia and New York) assigned on same engine company for 23 years now
Old 08-05-2013, 10:06 AM
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So I picked up a new vacuum reservoir the other day and put it in .... quick 5 minute job. When looking at the old box I put it on a vacuum tester and it would not hold a vacuum. Found a cut in the rigid vacuum line coming out of the old reservoir box. Once replaced I hooked up the boat and took it on the highway for a few miles and not a peep out of the front hubs.

Only thing I can think of is I must of originally had a bad solenoid or large leak in one of the main vacuum lines cuz when i replaced those two items the noise stopped except for when towing the boat. The break in the vacuum line coming off of the reservoir box was probably small enough to still hold enough of a vacuum under normal driving conditions but when I added the weight of the boat it would not hold.

Thanks to all for the input and help .



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