As seems to be a common problem on this site my 04 F150 had a solenoid go bad for the 4wd, which caused the 4wd to stop working. However, the dealership also says an actuator in the front hub is also shot and they recommend replacing both actuators (each hub).

A couple of times over the past 6 months I have heard a grinding and then a clunk, which goes away after stopping, I was never in 4wd when this happened. Is this what what would cause the actuator to wear out, and what other damage, such as to the hub could this have caused?

 

I just had the IWE Solenoid replaced under warranty on my 2007, mine was doing the same things as you described, the dealer installed a new updated solenoid that is less suseptible to moisture, problomo fixed.......

 

The grinding you heard was the IWE's being locked while in 2wd. Default position for the hubs is locked. If the solenoid or hubs are not disengaging while in 2wd, they will grind. Would not be surprised if the hubs were damaged.

 

Same thing happened to my 2006 this past spring, luckly I was near the dealership where I bought it and dropped it off. The dealer replaced the actuator and checked the front end, everything is working ok.

 

problem is when they don't get full vacum the gears( in the hub and the IWE or Integrated Wheel End , which is what they are calling the actuator) are partially engaged and they wear down.

 

I had the same thing replaced in my '06. I hope its an updated part also. They didn't seem to update it since '93 when I had the same problems with my Ranger.

 

That was the 1st time in 14,000mi that I had to bring it in for anytype of warranty work whatsoever other than normal maitenance.......I cannot say that for any new vehicle I ever had before....domestic or foreign.......