Occasionally rattling/clicking noise from front powertrain/differential

[hillerflo]

Hello Ladies and Gents,

for over a year now I have a problem with a occasionally (every 15 ish rides) rattling front powertrain/differential. I can not actively reproduce this error.
It occurs at slow speeds (25mph or slower) and when initiating turns. Then it starts klicking and then rattling like in the video. THIS VIDEO EXPLAINS A LOT HOW IT SOUNDS!

The noise sticks until I go in 4A (4 wheel drive).. then it is gone, even when going back to 2WD!
I had the truck 2 times at a Ford dealer for repairing/ figuring out the problem (5weeks in total) without results, so I'm asking here for help.

Additional info:
- It's a 2020 2nd Gen Raptor with the 802A and the Front 4.10 Trodden Diff
- In winter it didn't happen at all
View attachment IMG_5591-3.mp4


I am very pleased to get a good conversation going and find the solution soon because I'll take this truck back to Germany and Ford sates in their Warranty for the drivetrain, that it only counts for USA, Canada and Mexico (I'm trying to convince them, to extend the warranty for Germany, cause their mechanics are to incompetent to find the solution)


Best regards
Florian

 

[Gumby]

Hello Ladies and Gents,

for over a year now I have a problem with a occasionally (every 15 ish rides) rattling front powertrain/differential. I can not actively reproduce this error.
It occurs at slow speeds (25mph or slower) and when initiating turns. Then it starts klicking and then rattling like in the video. THIS VIDEO EXPLAINS A LOT HOW IT SOUNDS!

The noise sticks until I go in 4A (4 wheel drive).. then it is gone, even when going back to 2WD!
I had the truck 2 times at a Ford dealer for repairing/ figuring out the problem (5weeks in total) without results, so I'm asking here for help.

Additional info:
- It's a 2020 2nd Gen Raptor with the 802A and the Front 4.10 Trodden Diff
- In winter it didn't happen at all
View attachment 456006


I am very pleased to get a good conversation going and find the solution soon because I'll take this truck back to Germany and Ford sates in their Warranty for the drivetrain, that it only counts for USA, Canada and Mexico (I'm trying to convince them, to extend the warranty for Germany, cause their mechanics are to incompetent to find the solution)


Best regards
Florian

here you go

IWE Bad? How to Check

This is a Quick and simple Test. You will need one of these Vacuum Hand Pump and a pice of vacuum line the correct size. I have and old IWE line. Start with either IWE. Remove the hose It is Here After removing the line/hose use the vacuum pump to pull 20-25 InHg of vacuum. Let this Sit 10...

www.fordraptorforum.com

 

[dleclerc27]

Hello Ladies and Gents,

for over a year now I have a problem with a occasionally (every 15 ish rides) rattling front powertrain/differential. I can not actively reproduce this error.
It occurs at slow speeds (25mph or slower) and when initiating turns. Then it starts klicking and then rattling like in the video. THIS VIDEO EXPLAINS A LOT HOW IT SOUNDS!

The noise sticks until I go in 4A (4 wheel drive).. then it is gone, even when going back to 2WD!
I had the truck 2 times at a Ford dealer for repairing/ figuring out the problem (5weeks in total) without results, so I'm asking here for help.

Additional info:
- It's a 2020 2nd Gen Raptor with the 802A and the Front 4.10 Trodden Diff
- In winter it didn't happen at all
View attachment 456006


I am very pleased to get a good conversation going and find the solution soon because I'll take this truck back to Germany and Ford sates in their Warranty for the drivetrain, that it only counts for USA, Canada and Mexico (I'm trying to convince them, to extend the warranty for Germany, cause their mechanics are to incompetent to find the solution)


Best regards
Florian

I'm going to second what Gumby said and I just fixed mine this morning. The IWE is (new info to me) seemingly a common issue, it was plaguing me for a week. I check the solenoid first and it was holding vacuum in the correct gearing (2), but not in 4 - good news. I then ordered the FoMoCo IWE Check Valve replacement (part number FL3Z3A788B) and replaced it, $30 at the dealership (less elsewhere, but I'm impatient) and a very easy install. Good luck!