LutzNutz

2004 FX4 with the electronic transfer case.

A few weeks ago I noticed a rattling noise when I put the truck into 4WD. When I'm in 4WD and the noise is happening it'll stop as soon as I switch back to 2WD, and when I switch back to 4WD it'll take between 2-5 seconds to happen. There are no abnormal noises in 2WD.

The lights (4x4 HIGH, 4x4 LOW) are illuminating, and all the relays and fuses test good. I can hear clicks and the transfer case clunk when I change into either 4WD mode. No codes.

When we lifted the truck on a rack yesterday, the front wheels weren't turning at all, even though the axles where. I'm assuming the rattling sound is from the hubs/IWE not engaging or just being chewed up.

so I guess my next step is to verify the solenoid, and then the actuators and hubs. Since it's both wheels though, am I wrong to assume it's the solenoid? Anything I should be checking out?

Here's a video I just shot of it:

grss429

test the solenoid, if you don't have the updated one with rainshield just replace it..

it's most likely going to be the IWE actuators... i've had both fail at same time as well...


theses hubs are pretty strong

LutzNutz

followed this guy's procedure for checking the vacuum system:
and I have good vacuum and I can free wheel the front wheels on a jack when in 4wd, so I guess IWEs are next.

techrep

iTrader: (1)

IWE's are toast .. replace them and hopefully you didnt tear up your hubs

LutzNutz

Yep, it was the IWEs. The rubber seal on the old ones had failed and they where full of mud.

Replaced them and it's back to running fine.

techrep

iTrader: (1)

Sweet.. glad your back up and running

ReaperHWK

Wow that sounds horrible. Anyway, I've replaced mine for a failure but it failed in the engaged position so it was quiet just that I couldn't disengage the hub.


On a side note, these IWE's don't seem to be "water tight" so getting water in that area doesn't seem like a good idea. If I was an offroader I'd think about sealing up the gaps with RTV or something (on mine I just used a layer of grease but mine rarely sees dirt/mud/water).

techrep

iTrader: (1)

there is a rubber seal in them...just after time it degrades..

tcruz0004

How was the process of changing your IWEs? I may need to replace at least one of mine in the near future and I was wondering about the price and time.

LutzNutz

It's not bad, if you've changed out front suspension parts before. Basically you have to remove parts until the wheel hubs are freed, so go ahead and plan on doing a full brake and front suspension job if they have any wear at all.