09 XLT 4x4 Actuator Problem
For about the last year I have been having some major issues with the 4x4 hub actuators in my 09 XLT 4.6 w/ 11,500 miles. I have had it to the dealer four times already for this same issue and it is creeping up again.
Initially the problem (while in 4x2) was a very loud almost grinding noise in the front of the truck under light acceleration going up hill. That then change to include light acceleration on almost any surface after i had maintained speed for a while (i.e. highway cruising then stepping on the gas a little).
Every time I've brought this in I'm told it is a problem with the hub actuators and/or vacuum system controlling the actuators. Within these four visits I have had the actuators replaced several times (including the last one in which I am told is a redesigned actuator as Ford is now aware of this problem), all the vacuum system related to the 4x4, as well as the solenoid controlling the actuators. The only way to get the noise to stop is by mashing on the gas or throwing it into 4x4 and then back to 4x2
The problem has now resurfaced after roughly 6 months. The noise is the same but I get the problem again after the truck sits at idle for a while (drive up ATM, running while in a parking spot waiting for someone to come out of the store etc)
I'm just curious if anyone has been running into this issue. I would assume so if Ford redesigned the actuators, but I figured I would have seen something about it on here by now. I did a search but it didn’t turn up anything related to this issue.