I have to agree, it looks like corrosion related cracking to me. If you live anywhere where salt is used during the winter....your IWE's will always need to be watched and replaced once you start hearing some grinding or rubbing noise.

Since I've owned my 04 and 80k miles later, bought with 60k on the ticker, I've replaced two driver side and one passenger side IWE's, one cv shaft, both front unit bearings, and the firewall controller. It's just part of the beast and something that needs to be kept after. Also if you have any play or a wore into bearing it will eat away at you IWE spline collar....so when you need 4wd it's not there.....ask me how I know...haha!!!

 

To the OP, Would you mind sharing your install experience and thoughts, and how much you spent in parts? Just curious.

 

Ya I'll post once I get it done. I'm still waiting to order the parts, tough time of year to come up with extra money but I found them for $97 each online and I shouldn't have to buy any other parts but I guess I'll find out for sure when I pull it all apart.

Also to the post before... Corrosion makes sense, definitely a lot of salt used on the roads and in the air since I live by the ocean. I am commercial fisherman too so my truck is always by the water. Plenty of reason to believe that corrosion is the cause.

 

http://www.ebay.com/itm/BRAND-NEW-OE...74b095&vxp=mtr

$84 and change delivered. Tasca is a reliable supplier. It's cheaper to buy off their eBay page because you can avoid shipping costs.

 

Your loosing vacum to your IWE'S causing them to try and engauge, as stated above pobably the IWE solenoid or bad check valve. Check the sticky on they system inthe link provided and the system is pretty simple.

 

Ok cool thanks for the tip.

 

That's pretty much what I figured. Solenoid should be here tomorrow. It's the cheapest and quickest thing to change.

I also have another interesting observation. With the truck off, both IWEs should lock to their respective wheel. The passenger side doesn't (same side the noise sounded like it came from). I cannot rotate the driver side half shaft, but I can rotate the passenger side.

If I start the truck with the ESOF switch in 2WD, both half shafts can rotate freely of their wheel. If I switch to 4WD, both are locked to their wheel.

So, the only problem is when the truck is off- the passenger side is not locking to the wheel. Even if I rotate it, it doesn't lock. Maybe the passenger side only seems locked when I put it in 4WD because the other side is locked and the front drive shaft cannot turn (without at least turning the transfer case internals, even in neutral). I'll have to jack up the passenger side front wheel to be absolutely sure that the IWE is locking that half shaft to the wheel. I suspect it may not be. I haven't had a need for 4WD since I bought the truck. The IWEs are not expensive or particularly difficult to replace, thankfully. Winter is coming soon!

 

I replaced the solenoid last night. This morning I had it in 4x4 on some gravel and only the rear tires spun. So, I think the right IWE is not locking to the wheel at all. Since the front differential is open, all the power to the front goes to the disconnected IWE and it's just spinning without turning the wheel. I'm going to jack up that wheel later today to see for sure whether it's locking or not.

 

Well, it was as I figured. The passenger side IWE is not locking to the wheel even if I remove the vacuum line entirely. I haven't taken it apart yet, so hopefully it's just frozen in place for some reason. Worst case would be that the teeth on the hub are damaged. I don't hear any grinding (other than once, momentarily) from up front.

Just ordered a new IWE from Tasca's eBay page. Their shipping on my last order was rapid, so hopefully it will be here by the end of the week and then I can tackle this before the snow starts flying.

I did confirm that the transfer case is locking in 4x4. I cannot turn the front driveshaft until I switch it back to 4x2, and then it spins freely. The driver side IWE locks to the wheel as it should, and both have vacuum when they should (4x2 mode, engine running) and none when they shouldn't (4x4 mode). As soon as I get it replaced I hope to report back that it's all fixed.

 

Following along. Great info. Take some pics during the repair and keep us informed. Thanks for posting!