I've had it with this horrible vacuum operated auto hub system. I have replaced my IWE solenoid and outer hubs now 2 times.

Today under very light mud conditions at a jobsite the right front hub actuator popped. Immediately disabling 4x4 via transfer case spin.

WTF was Ford thinking with this system?

Why can I not find some smart person who has figured out a manual hub conversion?

Please help me as I am tired of replacing these parts, for them to just break again down the road.

 

You're saying your 4x4 popped and didn't work? Failure mode is for actuators to engage and give you 4x4. If the solenoid lost vacuum you would have 4x4.

 

The right Actuator popped.

Now I have the familiar gear grind noise on the right front.

4x4 wont work as the axle shaft is spinning because the damn hub wont lock in but of course it says 4x4 is engaged.

Manual hubs would fix all this nonsense.

 

Just disconnect the vacuum lines, the hub will engage then and you will 4x4 again. I've never heard of a hub failing to the disengaged position before but I guess it's possible.

 

I have a whole thread on this situation look at my post about it. It's a really easy system once you figure it out!

 

I'm not entirely sure what you think happened. If you replaced the hubs twice and the solenoid twice, but are still having issues, then you need to find out what is really going on. A proper diagnosis can save a lot of time and money.

 

Sounds like you need to do some reading and find the real cause of your IWE failures
https://www.f150forum.com/f4/4x4-tro...g-guide-39789/

 

Replace your vacuum check valves. There should be 2.

 

There is 4 check valves. 2 going to the solenoid, 1 going to the hubs, and 1 going to the reservoir box. I'm pretty sure at least, I just replaced every single part in the whole system to fix my 4x4.

 

As far as I understand, there shouldn't be a check valve going to the resevoir. Vacuum needs to flow in and out of it, otherwise it's pointless.