I hope it's that quick of a fix. I kids hope they don't try to pin it on the leveling kit if that was what caused the problem and not consider it a warranty item

 

I'm sure you will be fine. Tomorrow in the daylight turn your wheels all the way to one side and look at the back of the hub/spindle see if you can locate the air line make sure its connected nothing looks bent or kinked. I could be wrong but I would think it has something to do with the actuation of the hub. Keep us up to date I curious to know whats wrong.

 

They said the right front assembly wasn't holding a vacuum to engage 4wd. They replaced it under warranty it was just annoying having to bring it in already. I have a grinding noise that comes and goes on my left front tire now. It matches the revolution of the tire when it makes noise. Sounds tin can ish if I had to describe it. When it comes it only lasts a short while then it almost snaps itself back into place and then its gone. I have a service apt scheduled next week to look at it along with changing the oil. Not going to bring up the moonroof issue until Ford comes out with a fix for that.

 

This is one thing I've always hated about the Ford 4x4 design. When select 4x4, it engages the transfer case & locks the front hubs. The vacuum system has shown to be unreliable over the past 20 years, lots of problems reported with it. GM & others when selecting 4x4 only has to engage the transfer case, no vacuum hubs or dumb crap like that. In this case the simplest design is best for reliability. Less moving parts, less crap to go wrong. Ford was smart, at least on the F250-350 you can manually lock the front hubs if the vacuum system fails, on the F150 you're out of luck & stuck.

 

What you are hearing is the IWE trying to engage and rubbing a little. Its a known issue and the game you will play is unless it does it for them they won't fix it. Playing that game now with the dealership.
If you switch to 4H when it does it it will stop and switch back.

 

So if I can't duplicate it they won't fix it? What a croc that is. Don't really understand why. Not like I would make something like that up if it wasn't happening. The dealer gets warranty money from Ford anyways so I am hoping I have good luck

 

Just looked up a video on YouTube of the IWE problem and that's the exact noise I am having so thank you for the heads up. Say they fix the IWE, is this a problem that is going to reoccur and be a PITA?

 

They won't fix anything unless they can duplicate it. So find a way or yes it will be a wasted trip.

 

Your guess is as good as mine. Ford has been using this type of system since 2004. They have had issues with it but usually it was after 6-10 years and water has got into the system and freeze/thaw has created an issue. (from my research) The IWE is actually plastic so it cracks you lose your vacuum etc.
There are several things going on here. a actuator, vacuum canister, check valve, solenoid. mine is intermittent so who knows where to start. is it vacuum leak? if so why sometimes yes sometimes no? is it electrical? solenoid?
The understanding I have gotten is they connect a computer with sensors to my truck that run to different parts of the chassis that will take readings and noise levels etc. It has to happen and be recorded in the computer to submit to ford before they can do anything.

Truck sat at the dealership from Monday night to Sat last week with them driving it twice a day and no duplicate. I pick it up Sat and it does it. Sunday it does it. Monday it does it. usually if I let off the gas it will stop. once it did not I had to switch to 4H and back to 2H.

My service adviser has told me he has no doubt it is happening. But his hands are tied.

Starting to lean towards asking for an ESP on this since I put 30K a year on a vehicle.

 

Along with all that stuff you mentioned, you still have the actual vacuum hub part that are prone to failure also. The entire vacuum hub system is a bad design.....it's like the 6.0 diesel of the 4x4 systems world.....lol