RLXXI

Man I wished they had that wireless version when I was doing NVH diag at the dealer, routing the wires from the older version was a pita and time consuming. As far as the xfer case is concerned, I'd have a trained Ford tech get a listen to it and explain to him how you pinpointed the sound and of course get them to test drive and see if there's a common issue related to it via running an OASIS report with your symptoms, might be as simple as replacing a seal or bushing.
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Pete Ewing

I can imagine it was a PITA using the wired version, I got mine through Amazon...since I don't have access to a lift or a pit, I had to get under the truck...not easy for me...next investment (after the xfer case), ramps!! Thanks for the suggestion. I'll swing into the mechanic tomorrow and hopefully they'll be able to let me know.

Rougen123

Interesting development -- the last thing I would have suggested to anybody was that the tcase was making all the noises. Do you think it was stuck engaged or something? You try draining that sucker? I'm new at this too -- I really can't imagine what would cause it to be making that noise at idle.

We have to do state inspection here in Texas too -- I suspect the procedures are generally the same for any vehicle that requires a safety inspection in any state. They want to ensure the vehicle is safe to drive and that it's standard safety features are functioning properly -- not inspecting things like wheel bearings...for future reference I wouldn't rely on safety inspections to catch much outside of abnormal brake function, lighting/ signaling capabilities, and tire tread depth...

Cheers though mate, I'm glad you determined the source of your issue. Sorry, we were all steering you in the wrong direction. Keep us updated on this tcase

Pete Ewing

Rougen123...the xfer case isn't making the noise at idle...it's making it at different times between 25 & 65 mph...and only after it warms up. No, I haven't drained it or anything yet, am going to talk with a mechanic later today to see what he thinks, and then get the estimate to diagnose and repair it. I hear ya about the state inspections...and generally I don't. Since I've been going to the same place for so long, I know which inspectors tend to be "****" about the inspections and they go over it with a fine toothed comb...and the guy that did it this year (back in May), he's one of them. As to steering me in the 'wrong direction', no apology needed, I asked a question and y'all were giving me answers and feedback...so, it's all good and definitely appreciated.

Pete Ewing

Ok Folks, still having the same issue. I've changed out the Transfer case with a used one (105K less miles than what's on mine), same noise, same volume and same intensity. Today, both IWEs have been replaced, same noise, less volume and less intensity. The latest question I have is this, are the axle(s) from the wheels to the the front diff, and the driveshaft from the front diff to the transfer case supposed to turn when NOT in 4WD? I'm slowly narrowing it down, but man it's getting costly. Next step (tomorrow) is to pull the IWE fuse (to shut the solenoid off) and see if that stops the noise. I tried that before (no difference in the sound), but since the IWEs had such an effect on the noise, figured I'd try it again. Thoughts anyone? I'd pull my hair out but I ain't got much let to do that.

Pete Ewing

Ok, so I checked the vacuum solenoid, and it's working as advertised. Am now thinking there's a vacuum leak or something's going on with the front diff. Any thoughts, suggestions, recommendations?

Blue2016XL

Did you check the check valve? Those have been known to work intermittently.

Pete Ewing

No, I haven't checked that...maybe I'll just replace it since i have to go return a core on a caliper anyway.

Pete Ewing

Ok, I just checked the check valve, it's fine. The replacement made it worse, so I put the old one back in. Am pretty close to wits end with this issue...am thinking there's not enough vacuum reaching the IWEs (does anyone know what the vacuum should be at the IWEs?), or the front diff, or the electronic 4WD system. The only thing that seems to have changed some is when I come to a complete stop, the truck feels like something has "shifted" and I can feel a "thud" (I don't hear it, just feel it) and it feels like how older trucks shifted from or into 4WD and has an associated small 'lurch'. So, still open to suggestions, recommendations, and advice. If I can't figure it out, I'm going to bring it to the shop and let them figure it out.

Blue2016XL

Can't answer the other questions but, did you make sure you put valve on in the correct direction? Otherwise, it won't work properly.