WTF is wrong with my 4x4! please help!
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Junior Member
Joined: Jun 2012
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WTF is wrong with my 4x4! please help!
Hey everyone,
So my 4x4 one day on the trail went out, loud bangs and what sounds to be like something isn't engaging when you put torque on the front end. At quick look nothing appears out of the ordinary. I looked on here, read tons of post and see people having problems with the solenoid behind the battery, so i replace that, nothing changed. I gave up and took it to the ford dealership to have it diagnosed, they came back saying both my front hubs needs to be replaced. Well I just spent all afternoon and $500 for brand new hubs. I take it to a little trail, put it in 4 low, the diff engages, i give it gas, and the second the front tires have resistance, BANG! the front tires stop grabbing. Nothing has changed. I'm at my wits end with the truck. I'm no pro, but i not how to turn a wrench, Has someone had this happen to them? What are my next steps? Please help
So my 4x4 one day on the trail went out, loud bangs and what sounds to be like something isn't engaging when you put torque on the front end. At quick look nothing appears out of the ordinary. I looked on here, read tons of post and see people having problems with the solenoid behind the battery, so i replace that, nothing changed. I gave up and took it to the ford dealership to have it diagnosed, they came back saying both my front hubs needs to be replaced. Well I just spent all afternoon and $500 for brand new hubs. I take it to a little trail, put it in 4 low, the diff engages, i give it gas, and the second the front tires have resistance, BANG! the front tires stop grabbing. Nothing has changed. I'm at my wits end with the truck. I'm no pro, but i not how to turn a wrench, Has someone had this happen to them? What are my next steps? Please help
Senior Member
Joined: Nov 2008
Posts: 4,654
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From: New Brunswick, Canada
Hmm I had a very similar problem. Only think I can figure is the gear on the hub or cv shaft is wore. You said you replaced the IWE right? Well it's like a inside gear that slides over the outside gear on the cv and hub to engage 4wd. There is not much contact when it's in 4wd so
One of the gears may be worn. Can you pinpoint where the sound is from?
One of the gears may be worn. Can you pinpoint where the sound is from?
Senior Member
Joined: Jan 2012
Posts: 198
Likes: 5
From: Melbourne, Fl
Hey everyone,
So my 4x4 one day on the trail went out, loud bangs and what sounds to be like something isn't engaging when you put torque on the front end. At quick look nothing appears out of the ordinary. I looked on here, read tons of post and see people having problems with the solenoid behind the battery, so i replace that, nothing changed. I gave up and took it to the ford dealership to have it diagnosed, they came back saying both my front hubs needs to be replaced. Well I just spent all afternoon and $500 for brand new hubs. I take it to a little trail, put it in 4 low, the diff engages, i give it gas, and the second the front tires have resistance, BANG! the front tires stop grabbing. Nothing has changed. I'm at my wits end with the truck. I'm no pro, but i not how to turn a wrench, Has someone had this happen to them? What are my next steps? Please help
So my 4x4 one day on the trail went out, loud bangs and what sounds to be like something isn't engaging when you put torque on the front end. At quick look nothing appears out of the ordinary. I looked on here, read tons of post and see people having problems with the solenoid behind the battery, so i replace that, nothing changed. I gave up and took it to the ford dealership to have it diagnosed, they came back saying both my front hubs needs to be replaced. Well I just spent all afternoon and $500 for brand new hubs. I take it to a little trail, put it in 4 low, the diff engages, i give it gas, and the second the front tires have resistance, BANG! the front tires stop grabbing. Nothing has changed. I'm at my wits end with the truck. I'm no pro, but i not how to turn a wrench, Has someone had this happen to them? What are my next steps? Please help
If you replaced the hub actuator on the inside of the knuckle and your solenoid was bad it could have caused damage to the gears on the outer bearing hub that has the lugs on it....The default position of the actuator hub is engaged in 4x4 that is why when the solenoid fails it partially engages or completely engages one or both actuators causing damage to the gears on the outer hub as the actuator hub is of harder material.
If it is not this I would be cracking open the front diff housing and looking at the gears.....
Last edited by Jerhelo; Jul 23, 2012 at 08:32 PM.
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Joined: Jun 2012
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@speeddemon86- only things so far i have replace is the 2 front hubs, the ones with the lugs on it. and the solenoid. When I had the sv shaft exposed, i saw that gear you were talking about, didn't look striped or worn. Also the sound could be coming from the hubs or cv shafts. ill try and pinpoint it in a bit.
@Jerhelo- I only replace the actual bearing hub, the one with the lugs. I haven't explored anything on the inside part of the knuckle. Is the actuator known to strip out?
Thank you both for your reply.
@Jerhelo- I only replace the actual bearing hub, the one with the lugs. I haven't explored anything on the inside part of the knuckle. Is the actuator known to strip out?
Thank you both for your reply.
Senior Member
Joined: Jan 2012
Posts: 198
Likes: 5
From: Melbourne, Fl
If the air lines are leaking you would be engaged in 4x4 as it is the default setting, the only thing a leaky airline would do is partially or fully engage your 4x4 system...
Try completely pulling the air lines from the front actuator hubs and see if the 4x4 engages...If you have the same problems, pull the front diff cover and look at the ring gear and pinion? Could have a broken tooth or two...
Do you have electronic 4x4 or manual lever?
If the actuator hub gears look square still and you changed the outer hub it may very well be the ring and pinion. The CV's are a possibility but I would assume the the ring gear first.
One other thing considering that they just swapped the outer hub, pull the front wheels off, remove the small 1" diameter dust cover on the center of the front brake discs and check to see it the small nut on the end of your CV is snug, it is supposed to be torqued to 20 ft/lb's....
If this is loose it will not fully engage the 4x4...The best way to do this is with the truck off, it will engage the 4x4 actuators, then align the outer hub so that the actuator, outer hub gear and cv gears are all meshed, then torque the small nut to 20 ft/lb's.
Try completely pulling the air lines from the front actuator hubs and see if the 4x4 engages...If you have the same problems, pull the front diff cover and look at the ring gear and pinion? Could have a broken tooth or two...
Do you have electronic 4x4 or manual lever?
If the actuator hub gears look square still and you changed the outer hub it may very well be the ring and pinion. The CV's are a possibility but I would assume the the ring gear first.
One other thing considering that they just swapped the outer hub, pull the front wheels off, remove the small 1" diameter dust cover on the center of the front brake discs and check to see it the small nut on the end of your CV is snug, it is supposed to be torqued to 20 ft/lb's....
If this is loose it will not fully engage the 4x4...The best way to do this is with the truck off, it will engage the 4x4 actuators, then align the outer hub so that the actuator, outer hub gear and cv gears are all meshed, then torque the small nut to 20 ft/lb's.
If the air lines are leaking you would be engaged in 4x4 as it is the default setting, the only thing a leaky airline would do is partially or fully engage your 4x4 system...
Try completely pulling the air lines from the front actuator hubs and see if the 4x4 engages...If you have the same problems, pull the front diff cover and look at the ring gear and pinion? Could have a broken tooth or two...
Do you have electronic 4x4 or manual lever?
If the actuator hub gears look square still and you changed the outer hub it may very well be the ring and pinion. The CV's are a possibility but I would assume the the ring gear first.
One other thing considering that they just swapped the outer hub, pull the front wheels off, remove the small 1" diameter dust cover on the center of the front brake discs and check to see it the small nut on the end of your CV is snug, it is supposed to be torqued to 20 ft/lb's....
If this is loose it will not fully engage the 4x4...The best way to do this is with the truck off, it will engage the 4x4 actuators, then align the outer hub so that the actuator, outer hub gear and cv gears are all meshed, then torque the small nut to 20 ft/lb's.
Try completely pulling the air lines from the front actuator hubs and see if the 4x4 engages...If you have the same problems, pull the front diff cover and look at the ring gear and pinion? Could have a broken tooth or two...
Do you have electronic 4x4 or manual lever?
If the actuator hub gears look square still and you changed the outer hub it may very well be the ring and pinion. The CV's are a possibility but I would assume the the ring gear first.
One other thing considering that they just swapped the outer hub, pull the front wheels off, remove the small 1" diameter dust cover on the center of the front brake discs and check to see it the small nut on the end of your CV is snug, it is supposed to be torqued to 20 ft/lb's....
If this is loose it will not fully engage the 4x4...The best way to do this is with the truck off, it will engage the 4x4 actuators, then align the outer hub so that the actuator, outer hub gear and cv gears are all meshed, then torque the small nut to 20 ft/lb's.
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Senior Member
Joined: Jan 2012
Posts: 198
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From: Melbourne, Fl
Personnally I think it is either a loose outer CV nut or a broken tooth on the ring or pinion gear...
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Joined: Jul 2012
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This sounds like the same or similar issue I am having. 2008 with Elec 4x4 for me. When in 2 wheel drive I usually have a medium pitched minor grinding noise, it's not a major grind but that's the best I can describe it. Sound is plain as day. If I engage 4hi it disappears. No more noise but in 4hi if I turn the wheel I get loud clunks/bangs. Seems Obvious to me something has not fully engaged. Not totally disengaging in 2 and not fully engaging in 4hi. The bang noises are even worse in 4lo. Before going to the dealer I'd like to try and fix it myself. I have replaced the iwe solenoid already, it did not help. Anyone??