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Message: <blockquote data-quote="Augster" data-source="post: 2018788" data-attributes="member: 19867">For one thing, you should NOT engage in 4WD at highway speeds on hard-surface roads, PERIOD!  This is per the manual, which explicitly states that it "can produce excessive noise...". So you've got two significant factors that could cause the mechanical issues you're describing by driving at excessive speeds beyond the design of the 4WD system, and while driving on dry pavement. Sounds may be more pronounced when turning the steering wheel, even the the slightest turn. Remember: we have 4WD and NOT AWD, which the latter is designed to operate at all times and conditions, on all types of surfaces.Secondly, the front axle on a Raptor is a limited slip, which would explain why if one hub is engaged, this may lead to the opposite axle shaft spinning when its hub is not engaged.I, too, had problems with 4WD: namely, that I did not have 4WD when I was on the trails, even though the dash showed it was in 4WD. So I had to school myself on how the how F-150 4WD system works. The main culprit was a solenoid valve that would not release vacuum.When engaging 4WD HI via the cabin selector switch, the first operation that occurs is a motor in the transfer case engages the front driveshaft. This will get the front axles moving at the same speed as the rear axle if the truck is actually driving on a surface (i.e. this does NOT work properly when you have all four wheels suspended on jack stands and troubleshooting this system in drive--trust me, I learned this the hard way). The purpose of this is to synchronize the axle/IWE rotation to the wheel rotation, which allows the next operation to occur. The solenoid vacuum release vacuum to the IWE whereupon the spring tension in the IWE will re-engage the gear on the wheel hub, which should occur with no grinding of the gears since the wheel and axle rotations should now be in sync due to the xfer case engagement previously.Having said all this, yes, it could be the case of one or both bad IWE's on your Rap. I seemed to experience the loud bangs and grinding as you, but at slow, several miles per hour speeds on dry pavement and replaced the suspect IWE and it seemed to resolve the issue completely, even though I could not find anything wrong with the replaced IWE.</blockquote>

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