andrewe539

Update: Yesterday I changed my transfer case fluid, I did not see any metal shavings in the old fluid. I'm still nervous to take the truck to the shop since I will probably hear bad news.

Does anyone have any thoughts that this is for sure a transfer case issue? Or could it be a quick fix that I could do myself. It just baffles me that it changed into 4L as normal and then after less than a mile of driving, shifting out of 4L cause the grinding and weird stuff.

Any help would be greatly appreciated.

Steelhead 6.2

Could be check valve! Its a cheap part, so for piece of mind might be worth the install. I am having same issues but its my IWE. Just had Ford do a vacuum service line, (whatever that is!) and put in a new actuator and noise is gone! I was going to get them to change the check valve for piece of mind too! but decided not too, as it was fixed

PerryB

I really doubt you have a T-case problem. If the IWE's aren't going in and out when they're supposed to, the transfer case will grind and bang because the front shaft isn't turning (and the rear IS) when it's trying to engage.

andrewe539

Did you have any type of ratteling fom the side you had the bad IWE?

I believe mine is the source of a rattle. Now if a bad check valve is causing that or the IWE being bad itself I don't know. I plan on changing both out just for good measure as you said.

andrewe539

That actually makes a lot of sense. Looking back on it, I had the truck in 4WD after the level kit install but it was always in 4H. Only time I ever put it in 4L is the same time I heard the grinding. The grinding and whining noise does sound a lot like something turning under stress and then locking in. Which is probably when the IWE locks in and if feel the jerk.

Two questions I do have.
When switching the 4L and I get the shift delayed message, I pull forward but my truck wont move even though the truck is in drive. Then I heard all the noises and then it moves again. Would the IWE not engaging properly cause all of this to happen?

I switched into 4L perfectly the very first time and I only first heard the noise when trying to come out of 4L. Would the IWE not disengaging properly cause all the noises to happen?

Thans for all the help. I am hoping the answer is yes to both questions. I would hate to spend a grand on a new t-case when I could change out an IWE for 100 bucks.

Blue2016XL

There are a few people on here that have resolve the IWEs engaging while in 2H by changing just the check valve. I'd give it a try.

To answer your questions, the manual does say that you may hear noises when switching and that it is normal. When it gives you the shift delay message and to move forward, it's because the gears in the TC are not in a position for it to engage. So, you need to move forward or back a little so that it can engage. This is also in the manual and probably says it better than I just did. I have yet to have that happen to me yet but, I suspect I'd hear a few more clunks than what I normally hear. Also, I don't always get noises when switching either but, I will get most of the noises going to and from 4L.

At least that is my understanding.

andrewe539

Yea I am going to replace the check valves tomorrow as a first step. I read the same thing in the manual but mine is more sever than gears changing and everything locking in. My buddies 50 yards away heard my truck whine and grind when I was switching out of 4L. I am really hoping that possibly having an issue with the IWE system whether a check valve or the IWE itself is the cause of all my problems. It makes sense that a bad IWE would not allow the front drive shaft to engage. It just very random that I hear the humming from the IWE so randomly, like once every two weeks or so or if I hit a hard bump.

Can a bad IWE rattle?

Also could my truck whining and grinding be from a bad t-case motor?

Blue2016XL

IWEs I believe will only give you that paint can rattle while moving if not being actively engaged. That is the only time I have ever heard a noise from them. They just move back and forth while vacuum is applied or released. So if you are sitting still, I'd adventure that it isn't them. It could be possible is something was broken I suppose but, then you'd have to be moving still. This thread gives a pretty good description on on how they work. Post #2 has a video.

https://www.f150forum.com/f72/how-di...m-esof-186872/

Now, the loud clunks I hear I believe come from underneath down by the TC. They don't sound like they come from the front. With the way sounds work when sitting in the cab with the windows open, who knows. My timing knock always sounded like it came from the transmission area until I got out and listened for it.

techrep

iTrader: (1)

This happened after you had a level kit installed... cause is them prying on an IWE to get you coilovers back in.. this happens all the time when the shop does not know what they are doing. When they pry on an IWE it damages the inner seal and they leak.. that is the noise you are hearing.. a partial dis-engagement.. vacuum holds the wheel ends out...dis-engaged. You truck makes more vacuum at idle than at 55mph..if you keep driving it that way , you will destroy the CV shafts. Replace both IWE’s sense you don’t know which is damaged.. you can troubleshoot with your vacuum pump.. at the wheel end .

Steelhead 6.2

Yes! I had a rattling that would only go away when I engaged the 4H. It's gone now after new IWE install.
Also, recently replaced front left tie rod after noticing a clunking noise and that resolved that too.