Ford raptor front differential

[Essam Riad]

Well, I hope I can find some support in this thread I will start with I got my Gen1 last summer and when I drove it in the desert and initiate pressure I started to hear a knocking sound specially when I apply pressure like getting out of a stuck or high revs in 1st gear. Sound is definitely coming from the front side axles or front differential. So first assumption was IWE delete. Unfortunately I Brock the axle nut in the process so I change one axle and installed the IWE eliminator from RCV

Again I started to hear the sound after that, not all the time but only when am stuck or getting if a stuck and ofc only when driving 4wheel in sand. So I couldn't replicate the sound in the street .

So my thoughts are going into the differential now, I faced another challenge that i chat with my garage and he told me if we can get some of the differential internals we can try to open and check what's faulty and swap.

Two questions:

1- are we going into the right direction?
2- he mentioned parts number 6, 9,10, 11 and 13 from the below link:

Differential for 2014 Ford F-150 | OEM Parts Online

ford.oempartsonline.com

I struggled to find those part numbers for my specific car. I know from the door sticker that my dif is the 4.1 ratio, but how to get the rest of part numbers? Any magic tool that can give me these information ?

 

[Chewie]

If both axles are good, the IWE kit is in, I would start by taking the front differential cover off with the vehicle off the ground. Inspect the fluid which drained out and the inside of the differential for metal particles.

Then obviously inspect the internals without removing the ring and pinion (#11) check the backlash and then end play. This will give you an idea if anything needs to be replaced. Initially I thought maybe bearings (#9) but once IWEs installed then you should hear the noise as soon as you start to move.

Your carrier (#6) could be the problem since you only get the sounds when under load assuming in 4wd low gear. The gear oil which comes out will be a good indicator if you have metal on metal contact/problem in there, as well as a bunch of crud in the bottom of the differential itself.

Hopefully this gives some thought into your problems from halfway around the world.

 

[Essam Riad]

That was a very good explenaning of the thinking mechanism, appreciate it chewie.

Today I tested again since I was in the desert and the sound was so obvious once I steer full and go left or right in circles very slowly, I washable to capture the sound also will post soon

 

[Essam Riad]

Here is a video I took couple of hours ago, I hope it helps. Sounds come when on feel steer straight is usually fine