i have an 04 fx4 2in. leveling kit not new to the site but first post. Have question any help will be good. as i am driving from the driver side wheel i have a noise that sounds gears trying to engage but not engaging all the way this happens while driving in 2x4 mode. the noise quits when i switch into 4x4 mode. no clue if it is the hub or air problem. is it something i can fix or a dealership. any suggestions will help.
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Sounds like you need to change your 4x4 solenoid. There is a TSB out for it. The problem is it gets water in it and they redesigned it to solve the problem. I had the dealer change mine and it was under $100 installed.
Try the search button, sure sounds like the vaccuum operated hub, plenty of right ups about the soleniod that you just changed. As mechanic, my question is the operation of the hub. Vaccuum to engage 4 wheel, or vaccuum to keep it out of 4 wheel? Good luck, hopefully answers are on the way.
I just went through the exact same problem, Ford has been having problems with these but not all dealers have experienced it. Member "pecahead" came through with the right diagnosis. I told my dealer and they finally fixed it.
I had the same problem with my 07 F150. The solenoid was covered with the plastic piece but the hubs were never changed. One week after buying the truck I had the same gear like grinding noise. They replaced both front hubs for the 4 wheel drive. Fixed the problem. two months now after they fixed it, im starting to get a noise again in the same area when in 2x4. It goes away when I put it in 4x4 but then starts to come back. Almost like its not holding the vac and its slipping out. Took it in and they have no clue. dropping it off in a couple days for the dealer to tear it apart. Replacing the hubs out of warranty costs $800.
I too, have heard the noise in the front hub (only once or twice). But my 4 wheel drive hasn't even been working. I have had it "fixed" at least 2 times (think its actually been 3) by my personal mechanic (not Ford) and it still doesn't work (I have found out the hard way 2 of the times). After over $300-$400 each "fix" this is getting a bit ridiculous. It this is a common problem, why isn't Ford correcting it (for free) like they did with the "advisory" (not recall) on the older model doors (when they were all cracking)??? It's deer season and bad weather is imminent and I need to have the 4x4 (we all probably know how worthless a truck is without it and no weight in the back). Any input would be helpful.