So I got 2” front strut spacers and went to install them. I failed due to time and weather. I couldn’t get enough room to install the strut with the spacers so I put it back to stock for the time being. I went for a drive and now I have a vibration and slight grind when doing 40mph.

I disconnected the brake caliper, upper ball joint, tie rod end, sway bar link. When trying to install the strut, I was pushing down the lower control arm but didn’t have enough room and never disconnected the axle nut on the wheel. I also put the truck in 4wd while driving and it took a good 10sec for it to engage followed by a grinding noise. I stopped and put it back to 2wd. I took a look underneath and I don’t see anything like the cv joint having pulled out (no discoloration on the metal from being in place 8 years). What could cause this?

 

You could have possibly ruined one or both IWEs.

 

would that affect driving in 2wd if they were to go bad?

if I bought a new cv axle, would the iwe come with a new unit?

 

Yes, even in 2WD if they aren't disengaging completely or the gear is busted.

I don't think you'd get a new IWE with a CV axle. I haven't bought a new CV axle so I suppose it is possible but, unlikely.

 

so you think by pushing the control arm down, I messed up the iwe

 

Disconnect the electrical connector (carefully) at the IWE solenoid.
Raise the vehicle and rotate the tire. Does it make noise? Does it spin freely, but with drag (it will be spinning the axle half-shaft and should be a little difficult to spin but should not grind, etc).
Confirm this at both front wheels.
Take it for a quick test drive, is noise still there?
If yes, either the IWE will not engage the hub or you have another problem that is not IWE related.


IWE is an individual item, not at all part of a half-shaft (CV joint). Probably noting with with your half-shafts at all.
Most instances of a failed IWE (any part of the system) is only evident in 2wd.
The system functions in that the hubs are locked by default. When you start the vehicle, vacuum pulls the IWE away from the hub. When any of the parts fail, the IWE will not fully retract -noises then occur from teeth rubbing together instead of being 1) fully connected or 2) fully disconnected.

Disconnecting the electrical connection will make it so the hub is locked 100% of the time. If it is fully locked, no noises should be evident such as grinding, etc.

 

If you pushed it down far enough for the gears to become disengaged and anything turned. It is possible that when you pulled it back up that the teeth were not aligned and the gear in the IWE broke. Not saying that is what happened but, is a possibility.

 

So I purchased the ford protect premium care extended service plan when I purchased the vehicle 8 months ago. I’m well within the time and mileage, would front axle cv and/or IWE be covered?

for a $100 deductible, may be worth letting ford fix it

 

This is the plan

 

Looks like they are covered. Question is though, are they covered by what may have caused them to fail?