Pete Ewing

I put it in correctly...as there's only one way to put it in (which is an aside) as it's has one line in and two lines out. Thanks tho.

Pete Ewing

Ok, so here's a quick update. Turns out, one of the sounds was due to a factory clamp on the exhaust, however, that wasn't the main culprit. I've changed out the IWEs, and I was getting a rattling sound from the right front. Turns out, the caliper (both sides) were not releasing properly and they, plus the lines, had to be replaced. When doing the brakes, the bearings were checked and they seem fine. Again, not the main culprit of the sound. The transfer case has been replaced, and with the clamp being fixed, the sound now is a low rumble with a vibration. It occurs anywhere between 20 & 50 mph, however, it's loudest at around 26 mph and when coming up a hill, or accelerating out of a turn. It doesn't do it down hill, and only momentarily when accelerating more quickly than "usual". Also, it rarely does it when I turn on the Tow/Haul (when the light is on). I am at a loss as to what's causing the sound, but it sounds like a low rumble, almost like a rock crusher, but again, it doesn't do it all the time...and not at highway speeds. Any other ideas/suggestions? TIA.

Rougen123

Rock crusher noise sounds like a wheel bearing -- I wasn't super convinced that it isn't that based on how you described bearings being "checked" when they did the brakes. If your calipers were this messed up then you potentially need to look at the rotors.

Pete Ewing

Ok folks, latest update to this issue. I drove my truck about 100 miles from home and was gone for almost a week. I drove it locally where I was, and then drove the 100 miles back. When I got about 2 miles from home, the noise stopped inexplicably. So, since the truck has 184K miles on it, I decided to change the bearing assemblies anyway, and I ended up changing out one of the new IWEs (right side). Well, I drove the truck for a few more days, no noise...then, just as inexplicably as it disappeared, it came back.

So, I've changed the IWEs, the bearing assemblies, the calipers (both sides) and the transfer case...and the noise is still there. Again, it's a low, growling, rock-crushing, grinding sort of sound, and it only happens between (about) 25 mph and 50 mph. Any other suggestions? My plan at the moment is to take it to a Ford Dealership and let them figure it out.

However, I still have a couple of questions I would like to know the answers to... 1) Are the front wheels supposed to "free-wheel" when the IWEs are not engaged? (The axles don't spin when not in 4WD) and 2) What is the vacuum readings supposed to be at the IWE solenoid and also at the IWEs?

Thanks in advance for any other suggestions you may have.

Blue2016XL

Rougen123

I can almost guarantee the ford house won't be able to replicate -- which is unfortunate. Based on your latest description of the sound -- I'm beginning to thinking something is intermittently vibrating/rubbing/resonating.

I just removed the heatshield on my spare because of this. It would rattle pretty frequently and make my truck sound like a bucket of junk.

Pete Ewing

I was thinking the same thing...I was (am) hoping this isn't the first time they've run into this issue and know what it is and can fix it. It seems to me that it only happens when the drive-train is under a load....pushing the weight of the truck. The shop I usually take it to are good, and they've had it up on the rack, started the engine, put it in gear, but couldn't get the sound to repeat...and when they've test drove it after installing the bearing assemblies, they didn't hear it. Strangely enough, it disappeared again yesterday. Based on the sound sensors I've hooked up to it, it's definitely coming from the transfer case. Oh well, I'm going to have to deal with it for a bit longer.

Turbo Kidd

Any luck on this? I'm having the same issues and i have replaced everything you did except the T-case.

Thanks,

OFCLDutchess

You ever figure this out? I'm having the same problem