I have a 2004 F-150 and occasionally I will get a grinding noise from the transfer case I believe, when I am in 2wd. I first got it to go away when I would come to a stop then there would be a slight clunk and when I started driving again then it would be gone. Then when it came back I placed the switch into 4hi and it would go away then I could switch back to 2wd and all would be good. It does not grind all the time, just once in awhile it will start and I place it into 4 hi and it goes away. The 4X4 seems to work fine when I use it, and 2wd seems to work fine when it is not grinding. Anyone have any ideas? Thanks for any help you all can give me.

Troy

 

The problem is with your integrated wheel end system. Do a search for "iwe" should come up with tons of results.