Stumped by 4WD problem

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Old Jul 4, 2019 | 01:13 AM
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Question Stumped by 4WD problem

I've been having a problem with my 2016 Expedition. When I drive, it sounds like the 4WD is engaged. If you've ever driven at highway speed in 4HI, you know that you can sometimes hear sort of a hum coming from the front end at highway speed. If I go fast enough, I actually feel a little vibration.

I don't want this to get confused with the IWE hubs being partially engaged. I don't get any clicking, grinding, or rattling noises.

So I did a test:

I jacked up the truck, spun the front wheels with the engine off, and they were engaged with the axle shaft making it spin.

Then I started the truck, spun the wheels again, and they spun freely.

The system seems to be working normally, but I swear the axle shafts are turning when I drive it down the road.

So I did what might sound like a stupid test:

I wrapped some blue painters tape around the front axle shaft, and attached it to the swaybar link. If the shafts turn, I'll know it because it will break the tape. I also drew a line on the shaft with a permanent marker for a visual reference.

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I backed the truck down the driveway, pulled back up, checked the tape, and it was still intact.

I then drove around the block getting up to about 25 MPH, pulled back in the driveway, checked the tape, and it was broke.

Thinking that the 4WD hubs were working, I then bypassed the vacuum solenoid so that the hubs were always getting vacuum. When I unplugged the hose, a lot of air escaped.




With the engine off, I jacked up the truck and spun the wheels again. They spun freely from the axle shaft because I still had the vacuum hosesstuck together. This tells me that the 4WD hubs are working, and that the lines are holding vacuum.

I then reconnected the solenoid, and checked the hubs again.

Engine off - hubs engage the shafts
Engine running - hubs disengage the shafts
Engine running and 4WD set to 4HI - hubs are engaged with the shafts.

WTH? Why are the shafts engaging with the hubs when I'm driving?

Looking at this from a different angle, is there a way that the transfer case can be engaging as I drive, and spinning the front axle shafts? It's in 2WD, but it has the 4A, 4H and 4L settings.
 
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