We had a similar intermittent noise, not speed related nor gear related. Although when on the highway it would rattle and then thunk whereas on a slower drive just rattle intermittently. Based on what I read here and other sites on the internet i figured it was some part of the IWE. First visit to dealer, no sound during test drive and therefor no trouble found. Second visit I got a student tech to ride with me and he heard it. The service center ordered parts and replaced the hubs and solenoid. Still not fixed. So on third visit the service center replaced the hoses. I asked why not check vacuum on the second visit to avoid my third and the service person said, they had to follow Fords procedure. Apparently this procedure leaves out vacuum tests and upsets the customer for no good reason. Another thing...when the noise happens, put it in 4 wheel auto and if it is an IWE related trouble the noise should stop. Essentially you're releasing vacuum to engage the hubs.