Roadblock007

I started getting a grinding noise while cruising on the drivers side at the front wheel. I suspected ABS. But I have since been reading about IWE issues and ran some tests. I have vacuum at the solenoid. The vacuum is present at the wheels. When in 2wd the front wheels free wheel. In 4x4 they lock up to the axle shafts. So far so good. All lines look good with no leaks.

My issue isn't not having 4x4. When the noise happens it only does it a few times for a second. So I figured I'd run it in 4x4 to eliminate a vacuum leak. It still makes the noise in 4x4.

Could this still be an iwe issue?

Thanks for the help.

Roadblock007

Maybe 1/2 shaft?

Ecobuilder

My first guess would be either the wheel bearing or CV joint.

After some time has passed, if it's the wheel bearing, it'll sound like you're in the midst of a bee swarm.

Roadblock007

It's a definate intermittent crunch or grind sound.

Arizona Tumbleweed

Mine were grinding and it was the hub and the hub lock that were stripped. I understand your axles lock in 4X4 but do they stay locked when under a load? I think the best way to find out it tear it apart and look. 'FordTechMaculoco' has a good video on YouTube showing the disassembly/assembly procedures. Couldn't have done it without him. I bought replacement parts on Amazon and saved a lot of money.

Roadblock007

Since the locked position (4X4) is a lack of vacuum, how would they become unlocked? Unless vacuum were somehow added.

techrep

iTrader: (1)

Arizona Tumbleweed

The 4X4 is engaged but the splines on the hub and hub lock are stripped. That is what causes the grinding noise. Go find a steep, sandy hill and try to climb it in 4X4 and see if the front tire spins. Below is hub and hub lock showing the splines that strip.

Roadblock007

My thoughts are that if I am going to remove the axle then I am going to do the actuator too. It's only 3 8mm bolts. Cost is about $200 total to do both on one side.

Arizona Tumbleweed

Here's what I bought. About $207 for BOTH sides.

HUBS:
ACTUATORS https://www.ebay.com/itm/Auto-Locking-Hub-4-Wheel-Drive-Actuator-Pair-for-Ford-F150-Expedition-4WD-4x4/192454822603?fits=Year%3A2004%7CModel%3AF-150%7CMake%3AFord&hash=item2ccf338acb:g:t~oAAOSwn4 5ZyhNm:rk:1:pf:1&frcectupt=true&autorefresh=true