I recently returned from a two week vacation during which my 09 Platinum sat quietly in the driveway. On Friday, going to run an errand, I was about a block away when I heard a terrible metal scrapping sound in the front end. It sounded like I was dragging sheet metal. I stopped and did a visual inspection of the underside, but found nothing. Although it ebbed, the sound continued, so I turned around and went back home. OMG, I thought, what's this?!?!

I took it to my dealer this morning. On the way, I noticed that if I went into 4x4 the sound went away. I was fearing my truck would be in for a extended stay.

I was very surprised when my dealer called not much more than an hour later. Fixed. A known problem with the vacuum hose to the front transaxle coming loose that prevents 4x4 from fully disengaging. There is a bulletin out on this that includes applying a special adhesive to keep the tube from popping off.

Anyway, very relieved and wanted to share.

 

Well, not so fast. On the way home from the dealer last night, at highway speeds, I could still hear a grinding. Much quieter and less frequent, but it was there.

SO, back to the dealer this morning. They just called, found out the vacuum unit was defective and had to order it. Will have it tomorrow. Fingers crossed this is the final fix.

 

Make sure the IWE has not been compromised from this unnecessary grinding. The vac line may have advanced the wear on this item prematurly.

 

Finally received my truck back yesterday. The vacuum valve was defective. The dealer did a much more extensive test drive this time. All seems well now.

 

Well, my truck is now back in the shop for the THIRD time. There is still a scraping noise - intermittently - in the front end. It typically happens at about 65mph, but it has also happened at lower speeds. Its not continuous and its someone intermittent (not EVERY time I hit 65). So frustrating!

I took a test drive with the mechanic this morning, but due to traffic we couldn't get about 55, so of course it didn't make the noise. They gave me a loaner and I told them if they continue to drive it at or above 65, they WILL hear it.

I've read where front differential problems are not uncommon in earlier F150s but I've not found any reference to this being a problem with 2009s.

Has anyone else heard or experienced this problem?

 

i have a small low speed noise like you said and of course dealer unable to hear it

 

JVOS,

Does any of this noise your experiencing appear to be worse during turns? I have a noise from the front end on sharp turns, say turning into a driveway that has a small bump on it, that sounds like the tire is hitting/scraping the fender liner? I have a 4wd with the stock wheels and tires on it.

 

No, that's not my symptom. In fact, driving down the freeway is usually when I hear it.

Just heard from the dealer. They've had it 3 days, taken numerous test drives and 'can't seem to hear the noise'. So they suggested that I come pick it up and next time it makes the noise, drive directly to the dealer and have the mechanic come with me for a test drive. Yeah right, like it'll only happen when I'm near the dealer. Maybe I'll carry a recorder with me.
Geesh!

 

I have this same noise and wonder if anyone has had the same and had it fixed. If so, what was the diagnosis/fix?

 

well look at it this way. The next time it goes to the dealer they will now have to do thousands in big repairs at fords expense, cause obviously theres an issue that the vaccum hose falling off caused internally.

Just keep driving it till it breaks, you have plenty of record they had an opportunity to fix it before failure. I know it sucks, but such is life with cars and trucks and dealers.