Hi, Everyone- I've been browsing the forums for several hours reading up on IWE issues as I seem to have run into some myself. I'm hoping someone can provide some advice on what to do as I'm a little confused....

I was having lots of groaning noise from my 2018 3.5L EcoBoost back at the start of the fall and finally was able to get in to the dealership. The noise seemed to be coming from both front wheels and I described it as a baseball card in bike spokes type sound. Turns out they replaced the IWEs and I believe they even did the rotors (I was told it was over $2,000 in parts, thankfully all under warranty). I was relieved that they had found the problem and thought I was all set.

Unfortunately, while the noise wasn't nearly as bad as it had been, I still heard a similar, intermittent noise coming from the front driver side wheel. I brought it back in and they apparently found an issue with the front differential and had to do a bunch of work on that (another $700+ in parts). Now, I thought I was really set. Turns out the same intermittent noise remains from the front, drivers-side wheel. What's particularly strange is that it tends to happen at the same spot during my morning routine... I will pull out of my garage and take my daughter to daycare and it will drive perfectly; no noise. I get to daycare, shut off the truck to go inside for 3-5 mins, and then when I come back out and start heading to work, the noise will start. It's a steady groan that I can feel in the steering wheel and beneath my feet. Similar to the baseball card in bike spokes or like you're driving on a grooved road. The noise will last for a few miles and then just fade away and the truck will drive perfectly. It fades away in almost the exact same spot each morning that it does it.

So I brought the truck back into the dealership and they have not had any luck in diagnosing the issue. I was actually able to replicate the sound for one tech who agreed it seemed strange, but apparently they need to have their service manager also hear it and of course it hasn't done it for him. They claim to have checked all the parts involved with the IWE system and can't find anything wrong.

After researching in the forums, I've come across some interesting information regarding the IWEs staying engaged to turn the front differential to get it up to the correct temp. So I'm wondering if that's what the truck is doing and what I'm hearing is actually normal? It just seems weird that I've never noticed it before (and, not to mention, that the service guys don't seem to know about this functionality). It also seems to be a sharp contrast from regular, smooth driving to be a normal occurrence. Apparently this function is referenced in the FSM; can anyone corroborate this?

I also found this thread: https://www.f150forum.com/f118/2019-...8088-a-451845/
where it talks about revised IWE operation strategy in the 2019 trucks and a revised "TCCM strategy" with regard to the IWEs. It says:

"2019 F-150/Expedition/Navigator vehicles equipped with four-wheel drive (4WD) have a revised transfer case control module (TCCM) strategy that will affect integrated wheel end (IWE) operation after initial start up. The TCCM will not energize the solenoid to supply vacuum to the IWEs after the initial key cycle and a driven gear is selected. The IWEs will remain engaged for 0.8 km (0.5 mi) when the temperature is above 0°C (32°F) and 3 km (2 mi) when below 0°C (32°F). The strategy changes were implemented to improve vacuum supply management and axle warm up in cold temperatures. The engine must run for a minimum of 5 minutes to build sufficient vacuum before performing any vacuum related testing. Refer to the Workshop Manual (WSM) Section, 307-08A - Four-Wheel Drive Systems - System Operation and Component Description for additional information"

There's speculation in the thread that this would also apply to 2018s like mine. Would this explain why I don't hear the noise during the first part of my trip ("initial key cycle") and then hear it during the second part after I've dropped my daughter off? The temps are probably applicable as we're in the winter months where I live. The distance of 2mi is also probably pretty close to what I'm experiencing. I don't really know much about TCCMs or key cycles; is it possible that the TCCM on my truck was updated when it was in the shop and now I'm noticing the noise since it wasn't present before. Shouldn't I hear it from the passenger side as well?

Any advice you can provide is much appreciated. If it's operating normally, great; I can live with the noise for a short distance. But if there's something that should be fixed I want to make sure it's done before the warranty runs out. Any ideas on what else should be checked?

I love this truck but these issues have been super frustrating and I really want to get it running right.

Thank you!

 

If you have IWE problem still, take it back and have the stealership fix it until they are not a problem any longer. Once the truck is out of warranty, do yourself a favor and eliminate the IWEs with an eliminator kit.

AK4wheeler

 

Interesting... I see the RCV kit after a quick google search. May be something I look into down the road. Do you have any personal experience with this kit? Recommendations?

 

Cold weather IWE strategy applies to all the 2015+ F150s, although the strategy may be different from year to year.

From the 2016 WSM:

The TCCM features a cold temperature strategy which is used to warm up the front axle in cold temperatures to improve driveline synchronization. When ambient temperature is below 32° F (0° C). IWEs will engage after initial key cycle and a driven gear is selected. Hubs will stay engaged regardless of 4x4 mode change for proximately 2 miles (3 km). Once distance traveled has been achieved IWEs will disengage if vehicle is in 2H. Distance traveled will reset only if the temperature is below calibrated threshold and another key cycle has occurred or customer shifted to park and back to a driven gear within the same key cycle.

 

I’ve been running them for a while on my 2015 after two sets of IWE’s. No more problems since.

 

Here's the latest strategy for the OP's, and a lot of us. Post #14
Probable AWE issue - is it okay to drive to dealer in this condition? - Page 2 - Ford F150 Forum - Community of Ford Truck Fans

 

Thanks for the feedback everyone...

Question: is the temperature based on the truck's exterior thermometer (the reading displayed in Sync) or is there a dedicated thermometer that is reading the temp in the differential?

Because based on what I've read, and after keeping a close eye on my odometer during my commute this morning, I think what the IWEs are doing is normal but there is something out of whack on my front driver side wheel... My guess is that when pulling out of the garage in the morning the temp is above the required threshold so the IWEs are not engaged, therefore no noise. When I get to daycare and stop the truck, the few minutes inside must be enough for the differential to cool down below 32 degrees and then when I start the truck again the IWEs engage. Turns out the distance from daycare to the exact spot that the noise has consistently faded out is 1.8 miles, or 3 km. Seems the IWEs are doing what they're supposed to but when they're engaged something in that driver side wheel is causing the noise. Perhaps it's out of balance, but if that were the case wouldn't I hear the noise even when I'm in 2H? Maybe it's a rotor?

 

The system uses the temperature measured by the AAT (Ambient Air Temperature sensor), So what you are saying makes sense because the AAT is a slow acting sensor.

 

Thanks, good to know!

 

Two things I'd do, get your TCCM flashed to the newest strategy, there's even a TSB on that, and replace the check valve. I'll try to find the TSB.