I replaced my drivers side IWE over the weekend. Everything worked as it should all weekend with no noises. Today, I started to get a god awful noise coming from the front drivers side tire area, same IWE I replaced. It sounds like a handful of gravel being shook up in a metal container. I’m assuming I need to replace the same IWE again but my question is, what can I do to make sure this doesn’t happen again?

 

Have you checked vacuum? It sounds like it may be partially engaged which causes the grinding.

 

No, I haven’t. I have replaced the check valve and solenoid, prior to replacing the IWE.

 

yeah your not getting enough vacuum to the hubs to hold them disengaged

 

To salvage the work you've already done, disconnect your solenoid so that the IWE stays engaged.
Was the mating ring on the wheel bearing/hub assembly in good shape? Curious if maybe the gear is worn and now the IWE is being chewed up as a result of a bad drive ring.

New IWE, solenoid and check valve and still a problem.....check vacuum line(s) for damage.

 

Another possibility. It has been reported in the past that replacement IWEs have come with to much grease in them. Those that reported it said that they removed the excess grease and the grinding issue went away.

 

I’m not sure what you mean by mating ring. I have in the last month replaced in order, the check valve, 4x4 solenoid, hub assembly and now the IWE. I will say that when I was tightening the nut on the half-shaft something popped. I assumed it was something seating but maybe that’s not the case. And yes, I know not to over tighten that nut!

 

If things weren’t aligned properly, meaning the gear teeth, you can ruin the IWE. I’d do an inspection of the IWE after hearing that pop. Shouldn’t do that.

 

Probably a poor description on my part.

Think of the IWE like a collar that connects two parts. The IWE stays engaged onto the hub assembly (hubs locked).
The teeth of the IWE lock onto the hub. Vacuum pulls the IWE apart. I guess I'm wondering if the hub gear is worn out and the new IWE teeth are not biting into the hub teeth.
I supposed if that were true, it would be noisy all the time though.

 

I replaced the hub about a month ago!