Pop sound from front left when using 4a

[CoronaRaptor]

Maybe torque to lower shock bolts, etc, IDK.
Turn your music up louder, lol.

 

[smurfslayer]

This issue would be hard to reproduce because traction control is very, very aggressive on the Jen Too. If you apply power in a turn and break traction, the computer cuts power before applying torque to the front wheels in 4a. I have a turn I regularly take in which there’s a dip mid turn and it collects gravel. 90 degree turn and normal or sport mode, 4a, if I gas before the turn, T/C cuts power. If I gas mid turn, same thing, if I wait to clear the turn, she up shifts, and waddles down the road unless I really pour on the throttle.

If I recall, I may have heard that pop sound before, but as you said, very random. Try disabling t/c as much as you can, get in sport / 4a for your next engagement with a service department.

 

[REX111]

The sound will not happen when driving in 2H. I don’t think torquing lower shock bolts would do anything. I’ll try and drive it in 4a with traction control off to see if I can get it to act up.

 

[CoronaRaptor]

If it doesn’t happen in 2 h then it definitely doesnt have anything to do with any of the suspension, it will be iwe related. Who knows if the tech did the replacement correctly or not. There is a certain procedure to follow as per @FordTechOne , which he has mentioned several times.

 

[FordTechOne]

Its possible that an IWE is not properly engaging when 4WD is selected. The IWE installation procedure is critical; if it’s not followed properly, the IWE will be damaged and cause a repeat issue. And yes, I have seen techs install them improperly.

Did they inspect the front differential?

 

[REX111]

Dealership first put a drivers side axle in, then they did the iwe/bearing on drivers side. Noise remains. They then did an intermediate shaft. Noise remains. Ford tech had the tech drain fluid on front diff(it came out clean) and drain fluid out of transfer case (it was black with metal bits). All the fluids in the truck were done at 50k. That when the put a new transfer case in. Noise remains. They had a ford specialist come out and put chassis ear on truck. He determined that the noise was coming from passenger side of truck. He replaced the iwe/bearing on passenger side. A week later the noise was back and sound exactly the same before all the work was done. The dealership then couldn’t get we in for another two weeks and then I was over 60k, and now service manager is informing me that the noise is normal. I asked him if it was normal from the start why would you install all the parts. It feels like they are trying to wash their hand of my truck. I’ve have to go back for 11-s22 on Thursday and ford customer support told me to call once my truck in back at the dealership. I have given videos to the service writer that you can hear the pop. Service manager said he would send them to ford.

 

[FordTechOne]

Dealership first put a drivers side axle in, then they did the iwe/bearing on drivers side. Noise remains. They then did an intermediate shaft. Noise remains. Ford tech had the tech drain fluid on front diff(it came out clean) and drain fluid out of transfer case (it was black with metal bits). All the fluids in the truck were done at 50k. That when the put a new transfer case in. Noise remains. They had a ford specialist come out and put chassis ear on truck. He determined that the noise was coming from passenger side of truck. He replaced the iwe/bearing on passenger side. A week later the noise was back and sound exactly the same before all the work was done. The dealership then couldn’t get we in for another two weeks and then I was over 60k, and now service manager is informing me that the noise is normal. I asked him if it was normal from the start why would you install all the parts. It feels like they are trying to wash their hand of my truck. I’ve have to go back for 11-s22 on Thursday and ford customer support told me to call once my truck in back at the dealership. I have given videos to the service writer that you can hear the pop. Service manager said he would send them to ford.

The fact that they did the IWE and hub bearing and it was quiet for a week points to an installation/workmanship issue. I’d be pushing for them to re-inspect that work!!

 

[REX111]

I drove my truck in an empty parking lot in 4A with Advance Trac off. The truck will almost always pop when making a left turn while under power.

 

[smurfslayer]

When you say “under power”, 1/4 throttle, 1/3, half ?

I can’t find a reason to disagree with @FordTechOne on this. It sounds like a workmanship issue here. My bet is that you would get the same popping sound in dirt/sand/mud under the same test conditions in 4H.

I think their reticence is because they don’t want to admit fault and eat the cost of the repair.

 

[REX111]

I would say 1/3 power. Imagine coming to a stop to make a left turn. When accelerating and making the left turn about 1/2 way through the turn it will pop.