Metallic rattle from front hub area 2017 Gen 2

[Sam_S]

Hello all, I have this metallic rattling coming front what I think is the front hub area. Sounds kind of like a loose shopping cart wheel going over a rough parking lot. It actually started in January and I heard it at freeway speeds as more of a metallic spinning/whooshing, followed by a “thunk” and it would be gone for a while. Now the sound is at slow speeds just driving down a street or parking lot. If anywhere that amplifies or reflects sound, like a parking garage, it is pretty freakin’ loud. Took it in back in Jan, when under 60k miles and they said they were unable to replicate it. Now, with it much louder, I brought it back and they could replicate it. Of course, now I’m at 64k and they don’t want to cover it under warranty. The tech said he thinks it’s the front hubs and he wants to charge $850 in labor just to tear down the hubs and see if he can find anything! I told him no thanks. Does anyone here have other ideas as to what it may be? I’ve seen some other posts about IWE check valves but not sure what sounds they are hearing. I will say, when it is rattling, if I switch to 4A, it goes away immediately. Also, any tips on how I should lean on the dealer to fix it under warranty since this looks and sounds like a repeat issue they did not diagnose and fix the first time?

 

[FordTechOne]

Sounds like an IWE that has become damaged from previous partial engagements (lack of vacuum). Once the IWE is damaged the unit will need to be replaced.

Not sure where they came up with the ridiculous figure of $850 to inspect the front hubs; labor time to diagnose the system and replace an IWE is 1.2 hours. Do you have documentation that you brought it in for the same concern under warranty and the dealer didn’t properly fix it? Ford warranty won’t cover that (repeat repair) but the dealer should, as it’s their responsibility to fix the concern right the first time.

 

[Donovan]

Definitely an IWE.

First heard this around 55,000 mile mark. Now I don't hear it as much the more I use 4A.

 

[Sam_S]

Sounds like an IWE that has become damaged from previous partial engagements (lack of vacuum). Once the IWE is damaged the unit will need to be replaced.

Not sure where they came up with the ridiculous figure of $850 to inspect the front hubs; labor time to diagnose the system and replace an IWE is 1.2 hours. Do you have documentation that you brought it in for the same concern under warranty and the dealer didn’t properly fix it? Ford warranty won’t cover that (repeat repair) but the dealer should, as it’s their responsibility to fix the concern right the first time.

Thanks for this. Any idea how much an IWE goes for if replacement is needed? The technician said the $850 was for 4 hours labor just tear down the hubs and basically see if he could find any issues. He engaged 4A while testing it and knows it went away then as well. Not sure why he isn’t doing honking IWE as well….
On paperwork from prior, they didn’t fix anything—they just said they couldn’t replicate the issue to troubleshoot. So they passed entirely and said bring it back if the issue persists, which it did and I did. Now they don’t want to recognize that I brought it in under warranty period and they couldn’t diagnose an issue that has persisted.

 

[FordTechOne]

Thanks for this. Any idea how much an IWE goes for if replacement is needed? The technician said the $850 was for 4 hours labor just tear down the hubs and basically see if he could find any issues. He engaged 4A while testing it and knows it went away then as well. Not sure why he isn’t doing honking IWE as well….
On paperwork from prior, they didn’t fix anything—they just said they couldn’t replicate the issue to troubleshoot. So they passed entirely and said bring it back if the issue persists, which it did and I did. Now they don’t want to recognize that I brought it in under warranty period and they couldn’t diagnose an issue that has persisted.

Tasca sells it the IWEs for $83 each; list price is $124. The quote of 4 hour disassembly time is absolutely ridiculous; realistically it’s 1/4 of that.

As far as getting it covered, the only thing you can really do at this point is bring the RO to the dealer and explain that this has been an ongoing issue since the last visit, and now it’s out of warranty. Start with the Service Manager; if you don’t make progress there, you’ll have to engage the GM.

 

[Sam_S]

Thanks again—much appreciated!

 

[Donovan]

Good to note.

 

[dweb27]

Thanks again—much appreciated!

Sam...curious if you got this fixed?... see this link (also attached)..pretty helpful to understand the issue: https://4wheeldriveguide.com/wp-con...inding-noise-replacement-service-bulliton.pdf

Not sure what year you have, but this vacuum 4x4 system has been in place for several years. I just heard for 2021's they went back to pure electronic system since there were so many issues with the vacuum system. Also attached is a more recent TSB 49355, which covers 2015-2020's.

I've been dealing with this too with my 2019 F-150....5x in the Ford shop (only 24k miles), the guys still can't get it right. They suggested "capping off" the vacuum system which locks in the IWE's full time with axles (CV's) spinning full time -- which doesn't seem right...

Anyone else have thoughts on this??

 

[FordTechOne]

Sam...curious if you got this fixed?... see this link (also attached)..pretty helpful to understand the issue: https://4wheeldriveguide.com/wp-con...inding-noise-replacement-service-bulliton.pdf

Not sure what year you have, but this vacuum 4x4 system has been in place for several years. I just heard for 2021's they went back to pure electronic system since there were so many issues with the vacuum system. Also attached is a more recent TSB 49355, which covers 2015-2020's.

I've been dealing with this too with my 2019 F-150....5x in the Ford shop (only 24k miles), the guys still can't get it right. They suggested "capping off" the vacuum system which locks in the IWE's full time with axles (CV's) spinning full time -- which doesn't seem right...

Anyone else have thoughts on this??

The vacuum operated IWE system has been around for almost 20 years, the issue is not design related, it’s misdiagnosis by dealers.

The TSB to cap off the vacuum system does not apply to Raptor. The dealer needs to perform the pinpoint test in the workshop manual to isolate the leak or faulty component.

2021 models have an all-new IWE system that uses electric actuators instead of vacuum.

 

[dweb27]

FTO....so whats your thoughts on capping the system though? Seems with the CV's spinning full time efficiency goes way down, and mileage too..