OK, I have been planning to do this for a while and finally had some time to get it done. Took about 2.5 days but I think it will clarify how this thing works for those unsure.

I happen to find some one line cut section drawings of the partial assembly in some Warn documents that I used for reference to solid model it. Incidentally Warn is the the company who invented this system for FORD.

As you look at the PDF, the top section is of the system in 4WD or with the engine off. The bottom section is the opposite. Pay attention to the bright colored parts to see what actually moves in the actuator and how the gears engage/disengage.

Hope this helps...

3D model of IWE assembly

 

Very nice.

 

I just wanted to throw out there, as a suggestion for all you guys having to chase down a leak - the whole vacuum line with new check valves and all, can be purchased from your local dealer. Some of you might prefer to just change the whole line (especially if you're up there in mileage) instead of trying to track down the leak. A "time-is-money" analysis might be worth applying here...

 

Thanks for the thread TN-F150,

Bookmarked it for further ref. now that teh warranty is over.

I had mine done on the drivers side a couple years ago.
Same thing, When it was cold out it would grind and switching it to Hi stopped it but would come back..
Dealer did it under warranty..

 

Wow, that is great for those who may have a leak. That would be my option if I did. I would much rather replace old parts with known good parts in a case like that. Replacing both actuators and the line and check could make it go for many more years to come.

Dang I miss my truck...

 

No problem. Besides, I may have started it but we all contribute to make it better.

 

Yeah, and if I remember correctly, it really wasn't an entirely unreasonable price... I don't have a part number, but it shouldn't be hard to track down.

At any rate, thank you for your contributions, TN-F150!

 

Great!

It's my pleasure. I don't even have either of my trucks anymore but this is one forum I still really enjoy coming back to.

 

Hey Guys,
So here is my problem on 2005 F150SCrew. I guess I should start off last year. I had the grinding sound on the LF actuator, replaced it and all good. Before I did that I did replace the solenoid up on the drivers side fire wall as well but that didn't fix this issue (although everyone said to replace it anyway for good measure.)

Now recently I have started getting a whinning (rotational sound) from my front end. It is NOT the grinding sound I had last year. I guess I would say that I might also be experiencing the "pushing the front end" feeling that some are reporting. Hard to say if this is the case of if I am imagining it. The whinning sound adjusts based on the speed I am going. I don't think it is the wheel bearings as the sound doesn't get louder when turning or changing lanes and I have jacked the truck up and the wheels feel tight. I put the truck in 4WD and the sound doesn't go away. If this was a IWE issue or vacumm issue, would the whinning sound go away when I put the truck into 4WD? I didn't full test to see if I was truly in 4WD - mearly just switched the truck into 4WD Hi for a sec to see if sound when away. I read the following post and wondered if this was my situation.

My actuator was shot to the point where vacuum wasnt able to build in the system at all so the wheels were always locked into the half shafts, those in turn were locked into the front diff and front drive shaft, but my transfer case was in 2hi, so the 4WD wasnt engaged. But while in 2WD the truck had to in a sense push the front cause the tires would move the whole front driveline. Holding back the truck in a way, and giving me alot of extra rotating mass, you get it?

Couple of notes: checked under the truck and can't find any grease or oil leak anywhere, live in Wyoming so it has just started to get much colder.

So - any thoughts? Should my first step be to test the vacumm again? If my issue was with the IWE, would the whinning go away?

Any thoughts on what else may be causing this sound? Thanks in advance for the help!

Bruce

 

The short answer, yes. If you turn the switch to 4WD and the noise goes away, it is the actuator(s). What you hear in 2WD is the actuator gear touching the hub gear because it isn't disengaging enough to keep teeth from teeth. When you switch to 4WD, it cuts vacuum completely and they engage, the noise stops.

As long as this system is on the truck, my bet is these will always be a problem. It is a clever system, but very weak and obviously problematic.

 

Clearly this system has issues. But as I said, when I go into 4WD, the noise doesn't go away. I completely understand how the system works as I did so much research last year and fixed one actuator last year that was grinding. From my understanding, the issues with this system is when the truck is in 2WD - not 4WD. Meaning, that the issues is basically keeping the truck from trying to go into 4WD. I am just wondering if the whinning (even when in 4WD) could be related the this system as well? I am thinking that my sound might not be related as the whinning (rotational) sound doesn't go away when I go into 4WD. Thoughts? And if you don't think my issue is with the IWE system and I don't think it is bearings, any other thoughts on what it could be?

Thanks!

 

My bad. I mis-read what you said. Mine got to the point that even when the truck was switched to 4WD, the noise would be there. It started out that when in 2WD it would and then stop in 4WD. My guess is based on that it could be the actuator(s). If it sounds different than that noise, that would be something one would have to hear in person. I have no guesses.

 

Thanks - I guess I am hoping it is an actuator - pretty easy fix and not to expensive. (meaning - don't have to bring it to the dealer) Gonna test the vacumm lines tomorrow. Will post the results!

 

Hey Everybody! So Iv been reading the forums for a long time now and have learned a lot. I need a little help. I'v been tracing a vaccum leak for a week now and I think it's the CHECK VALVE at the solenoid. I can blow through both ends. Does anybody have a part number? I can find one at Napa but its too small. None of the local Ford part dealers can find it in their computer unless I can give them the part number. Thanks for any help.
2005 FX4

 

this talk makes me worry, i have a slight wine, but 4wd works.