My 04 FX4 5.4L has been making an intermittent grinding noise for a couple of weeks. Other posts lead me to think it's the IWE Solenoid. I've read it accurately described as "ice cubes in a blender". The noise disappears as soon as I flip to 4WDH. It does not appear to be temperature or speed related. One day it will happen 3 or 4 times, then be fine for a week.

The truck is still under warranty, but of course the problem didn't happen while it was at the dealer for 2 days. He claims there were not error codes logged. A few questions...

Is it true what the dealer says about the codes? Will this problem be recorded in some sort of memory?

Cant the dealer proactively replace the solenoid based on my description (he said no, he has to hear it or see a code)?

Is the grinding from the solenoid itself, or am I actually grinding gears?

Any suggestions would be helpful.. !

 

We also have the same loud grinding noise, never know when it will happen or if. Dealership had the truck for 2 days, we went to pick it up and the service manager tells us that he couldn't get it to make the sound and that he can't fix it ubtil he can verify it. What is it going to take, the wheel to fall off going down the interstate and hurt or maybe kill someone???? We can switch it from 2wd to 4wh and it quits, or put the brake on and pull over it disengages and then we can pull back on the highway. It sounds like a major deal when you hear it. How much more veriification do they need. Good Luck on getting it fixed

 

Have them check the 4 X 4 Vaccum switch on the passenger firewall. They replaced mine and the grinding disapperaed. Also have them check the hubs for any damage.

 

My dad has a 96' dodge ram 1500 4x4 that does this also. Could I tell him to check the vaccum switch or is it different for other trucks that isn't a Ford?

 

Hey Sarnan, I'm having the same problem with my T-case and was wondering what if anything did the dealer do to remedy the situation.I took mine back 3 times and it wouldnt do it for them.Whats this I hear about a "4x4 motor".
I'd appreciate any info you could give me to get this fixed.I about had it with this truck.

 

lauhtgac - see my post to your other question in this forum for an update to the saga.

I'm told the 4x4 motor is what drives the transfer case to engage the front wheel drive. On older trucks it was manual.

 

I have a 2004, at 63000 it started to make the same noise and finally it droped into 4x4 all on it's own, took it in and they couldn't find anything (cost me 50.00). Two days later it droped in so hard that I could feel it in the shifter, back to the dealer, they tell me it is the pump that engage the 4x4 that has failed, $800.00 they will pay 75% I paid the balance. They say that they inspected the hubs for damage and they are ok, but I have a no fath in the system any more it now makes a noise that is new, nice truck but i'm going to sell it if I have any more problems.

 

I have the same noise.. In the beginning it was just a one or two second metal grinding noise that would happen now and then... I took it to the dealership for 15k checkup and they couldn't get it to make the noise and that they couldn't do anything until they hear it.

Nowadays it does it maybe once a day but the grinding won't stop until I slow down quite a bit or slow down and turn, during which I can hear a moaning sound, a couple of clunks, and then the noise goes away. Just the other day I discovered I can switch it into 4wd and the noise goes away, then I switch it back.

I'm going to contact the dealership to let them know what I've discovered and tell them I've read a few things about my problem. Looks like this might be a common thing, especially with several people in this thread having the same issue..

Dave

 

From the service manual:

Condition:
The front axle does not engage/disengage correctly/makes noise in 2H under heavy throttle


Possible sources:
Mode select switch.
Integrated wheel ends (IWE).
IWE solenoid.
Vacuum leaks.
4x4 module (PCM).
Front halfshaft

Go to pinpoint test K:

PINPOINT TEST K: THE FRONT AXLE DOES NOT ENGAGE/DISENGAGE CORRECTLY/MAKES NOISE IN 2H UNDER HEAVY THROTTLE


It's about 13,000 characters..... way too long to post here.....

Basically, based on my limited knowledge of how the system works, the GEM grounds the vacuum solenoid on the firewall to DISENGAGE the IWEs. There's only a couple things that can be causing them to grind: Lack of vacuum, or sticking IWEs. If the IWEs are bad, that'd be a simple thing to check. If the solenoid is sticking, or there is a vacuum leak, that's a little tougher to track down, but not impossible.

The best way to show the dealer what it's doing is to wait until it's doing it, drive it right to the dealership, leave the vehicle running, and go get the service manager to come out for a ride with you to show him what it's doing. It's a bit inconvenient, but it's the only way to prove you're not insane.

In the dealership's defense, these kinds of intermittent problems can be very very difficult to diagnose. If they can't reproduce the conditions, how can they diagnose the problem? It's like if you go to the doctor and tell him/her that your knee hurt yesterday, but it's fine today, please fix it..... it doesn't work.

-Joe

-Joe

 

Thanks for the info from the service manual.. Although it doesn't make the noise under heavy throttle, and I can put it into and out of 4wd without problems (that I can tell). The roads were a little snowy last night and in 4wd I accelerated what seemed normal for 4wd mode, so I'm guessing the fronts engaged the way they normally do.

I'd love to be able to take it to the dealer while it is doing it, but if I slow down enough while it is making the noise it stops, which means the dealership is not going to hear it because it won't be doing it when I get there. If I'm lucky it will do it once a day. It starts making the noise and once I slow down enough it will moan, clunk a few times, and go away. It mainly happens while maintaining a constant speed or while coasting. I drive 20 miles each way to work and unfortunately it could do it at anytime. Maybe if they loan me a technician for a day or two, then they might get to hear it..

I completely understand where the dealership is coming from. I'm the help desk for my office and I know it's nice to be able to "witness" the issue in person. But in my case I've narrowed it down to what seems to be an issue with the drivetrain. Now they need to take it, drive it for hours if need be, and fix it..


Dave

 

I feel your pain, man, believe me....

Here's a thought.... for anyone that might be interested, if you unplug the vacuum solenoid that controls the IWEs, and switch to 4high, does the GEM see the problem and throw a trouble code? Regardless of the code (which I think could just be bypassed with a paperclip) could you just unplug the connector on the solenoid, let the IWEs engage, and run it like a live axle? Anyone think it would do the front end any harm? I mean, other than costing one mpg or so, is there any real advantage to a dead front axle?

-Joe

 

note: Iam have it repaired for the second time today, it is out of warrenty and ford is paying all but $70 so they know they have a problem, on the first go around they paid 75% of a $800 bill, just wish I was confident there is not any further damage.

 

What are they replacing?

 

I took my truck back in a couple weeks ago for the grinding sound and for my still squeaking rear sliding window.. The service advisor had no clue what was causing the grinding and said he hopes they can fix it..

I dropped it off first thing on a Friday morning. I contacted him later in the morning while I was at work and shared with him some things I found online over the past couple months.. I mentioned vacuum problems, IWE solenoids, etc.. He said they would check it out. Later that day he calls and said the an IWE solenoid was bad and it would be ready Monday. It was ready that Monday and I haven't had a noise since.

Just thought I'd share.

Dave