I have been researching and have come to the conclusion that I need to put on new 4wd actuators.

Problem:
Metal sound when in 2wd, goes away in 4wd. Sounds like I am dragging a piece of metal. Sounds like passenger side
2005 Ford F-150 FX4 5.8 V8 4WD

Here is what I have done so far for troubleshooting:

1. Put truck in 4wd - sound goes away, hear and feel clunk on drivers side when engaging
2. Replaced solenoid - same result
3. Tried bypassing solenoid - same result
4. Unplugged vacuum lines from solenoid - noise goes away

From what I have done, do you suggest that the Actuators are bad? I will replace both if I am going to be doing it.

I am looking at part numbers 7L1Z-3C247-A for OEM and 600-105 for OEM replacement. Which do you suggest?

Thanks
Jason

 

Have you checked the vac lines for leaks? If it still does it while bypassing the solenoid, I would be looking for vac leaks, then finally at the actuators themselves.

 

I will try checking for leaks next.

When bypassing the solenoid I was still getting the sound.
But when I leave the vacuum line loose, and unconnected, the noise goes away. So, I guess it is keeping the actuators locked into the hub since there is no vacuum...right?

So, hopefully it is just a vacuum leak that is preventing the actuator from pulling all the way back and is hitting teeth in the hub.

Sound right?

 

Did you try a vacuum check on both actuators? That's how I found my problem, had the same symptoms. Ended up replacing both. There is a ford dealer parts warehouse out of Florida that will sell the actuators for $85 each.

 

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

https://www.f150online.com/forums/20...replacing.html

 

Yes, the IWE's lock when there is no vacuum. So what you most likely have is a vacuum leak somewhere leading to partial actuation. Keep in mind though that a partially engaged IWE will eventually grind itself up, so if you've been grinding for a while, fix the vacuum leak, then check the IWE to see if it's wiped out.

 

Don't forget to check the solenoid on the fire wall. As said before if it grinds too long you'll need a new actuator and maybe a hub.

 

any luck with the problem? i just got done installing a lift on my truck, after cycling through the 4wd it start making a noise like gears tryig to engage. i googled it and narrowed it down to the IWE or the soleniod..

 

i had mine making the same noise, took it into the dealer a few years ago while it was still under warranty. they replaced the solenoid on the firewall. about a year ago i was having problems with my 4wd not engaging fully and would pop out when the right front wheel had to work. after replacing the transfer case shift motor i still had the problem so i put all 4 wheels on jack stands and put truck in gear in 4wd and finally figured out the right front wheel wasn't fully engaging. when i tore into it thinking it was the hub i found the actuator had broken apart and wouldn't slide evenly so i ended up replacing the hub and actuator. haven't had the issue since. so yes i recommend checking the wheel end actuators

 

OP, Did you ever get your problem fixed?