I have an 05 FX4, and I discovered the other day, after getting stuck, and having to be pulled out by a Chevy, along with all of the requisite smack talk, that for the second time in the last two years one of my IWE actuators is not working, and causing my truck not to engage the 4 wheel drive. Is there a more bullet proof upgrade that can be made to the system on our trucks so I don't have to find out the hard way that something has gone wrong? Are there any manually locking hub conversions, or recommendations on how to make these things stronger, etc.? I'm not hard on them or anything. I never full throttle it in 4X4 mode or anything. I'm sick of this crapp. Please help.


Doug

 

Short answer: no. Get new IWEs and install. It's actually a fairly straightforward process. Once I saw what they looked like on the inside, I never wanted to "shift-on-the-fly" again.

With that said, it is rare to see an IWE that is NOT engaging. Usually, the issue is in the other direction. With vacuum removed, the IWEs engage. When you start your truck, the vacuum pulls the IWEs off of the hubs. If you have an IWE that is not engaging, then that IWE must be stuck open somehow. This is NOT what most have experienced. Are you sure you aren't experiencing a transfer case/engagement problem or some other kind of issue like a failing IWE solenoid? You might get off the hook easy by simply changing the IWE solenoid (located on the firewall, behind the battery). It's a $30-$40 part. If the solenoid isn't "closing" correctly (to release vacuum), then your IWEs will stay engaged constantly. If neither hub is locking, then I would bet your issue is with the IWE solenoid or maybe even an electrical issue (a fuse, maybe) not allowing the solenoid to function properly and thereby not allowing the IWEs to engage properly.

 

thanks, that's kind of what I was afraid of. Is there a way to test whether they are engaging or not without getting in loose soil or mud or getting all four wheels off the ground? In either case though, if the front wheels are not engaging, I should be able to just pull the vacuum line off of the solenoid and engage them, correct?

 

Yes... if you pull the vacuum lines when out on the trail, the front wheels will be engaged. Don't fret, though. Your issue doesn't sound nearly as complex as it could be if, say, one of your IWEs was engaged all the time, as that would suggest a vacuum leak (which can be a bear to find).

You can test by raising the front end and removing the vacuum line on each side (and not necessarily simultaneously - you can test each side individually). Once the front is raised, you should be able to spin the front wheels, and if everything is working correctly down there, the half-shaft should spin as you spin the wheel. I suggest you pull the vacuum line to test, even if the vehicle is off. My experience has taught me that if your check valves in the vacuum lines are still kicking strong, there still me be enough vacuum to pull the IWEs off the hubs even with the engine off (at least, for a little while, until vacuum escapes entirely). If you look at a diagram, you'll see what I mean.

Honestly, get over to your local dealer, purchase the solenoid for a few bucks, and then install it (which will take you all of 3 minutes). Maybe the solenoid isn't bad, but it is worthwhile to change it on an '05 at this point, anyway. In fact, there was a redesign of the solenoid, so you may still be using the older style that allowed water to creep into the vacuum lines.

Good luck, man. We're not going anywhere. Let us know what we can do to help.

 

thanks. I'll give that a shot, when I get a free minute. Thanks for the quick response.

Doug

 

a good trouble shooting guide;

http://www.ford-trucks.com/forums/83...then-some.html