Humming/Grinding Causes/Thoughts

[Tayloroct09]

Hey guys,

Wanted to get some opinions on the issues I am having with my 22 Tremor. I have been having the dreaded humming/grinding noise coming from the front end for a few months now since my last off road trip. The noise comes and goes intermittently and does change based on 2wd/4wd selection and throttle input. I took the truck to the dealer and they said the front ring and pinion gears were stripped and had a chunk missing. They replaced the necessary parts and upon pick up the truck was still exhibiting the same noise. I ended up taking the truck to the other local dealer since the first dealer was treating me like crap and giving me the run around. The second dealer is much better luckily. They diagnosed the truck and said the IWEs needed to be replaced and completed the repairs. A week later I pick up the truck and the noise is still there again, just quieter. Fast forward another few days and the dealer calls me and said the front differential has metal shavings and will need to be torn down and inspected. My gut feeling is that there could still be an issue with the IWEs due to the strange nature of the 2wd/4wd habits. If you drive the truck at a certain throttle input it'll make noise like crazy and will go away as soon as the throttle is released. I don't understand how the noise could occur all the time if the truck is in 2wd and the front drivetrain in theory should not be spinning. I could see an iwe causing the constant noise, but if the differential truly has metal shavings then could something else be happening?

Just wanted some thoughts. Thanks

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[Riddick]

Disregard, I posted on the wrong thread.

 

[obert]

The front differential is basically always spinning while driving. The IWE will in gauge along with the transfer case to give power to the front while in 4WD.

I had a similar noise and it was the front differential and the dealer rebuilt it.

I thought it was the IWE as well and went ahead and replaced my self before a dealer trip and the noise was still there.

Someone on here just had the torque converter replaced because it was making noise.

I think

 

[513Mugsy]

Well you said that the front diff has been rebuilt and the IWE's replaced. I am kinda leaning towards the pinion bearing in the front diff. The throttle on off causing the noise to come and go leads me to this. When you load up the pinion it loads up the bearing. And if they are still finding metal in the oil, either the dealer didn't cleanup well before the rebuild, or the bearing is going.

 

[Tayloroct09]

The front differential is basically always spinning while driving. The IWE will in gauge along with the transfer case to give power to the front while in 4WD.

I had a similar noise and it was the front differential and the dealer rebuilt it.

I thought it was the IWE as well and went ahead and replaced my self before a dealer trip and the noise was still there.

Someone on here just had the torque converter replaced because it was making noise.

I think

Interesting. I would think that the front differential would be stationary when the truck is in 2wd. Does anyone have any idea how these transfer cases work? The truck has 4A and I know I've seen something about some clutch packs or something internally.

 

[Tayloroct09]

Well you said that the front diff has been rebuilt and the IWE's replaced. I am kinda leaning towards the pinion bearing in the front diff. The throttle on off causing the noise to come and go leads me to this. When you load up the pinion it loads up the bearing. And if they are still finding metal in the oil, either the dealer didn't cleanup well before the rebuild, or the bearing is going.

That would make sense. I've read others having issues with the pinion bearing as well, and as you said it comes and goes under different throttle loads, under very light throttle you wont hear anything but with a little more throttle it makes noise like crazy and if you really get on it even harder the noise goes away. Very strange in my mind. But it wouldn't surprise me if the previous dealer missed something. After the issues I've had with them I did some research and they don't have a good track record.

 

[JumboJVT]

The front differential is basically always spinning while driving. The IWE will in gauge along with the transfer case to give power to the front while in 4WD.

I had a similar noise and it was the front differential and the dealer rebuilt it.

I thought it was the IWE as well and went ahead and replaced my self before a dealer trip and the noise was still there.

Someone on here just had the torque converter replaced because it was making noise.

I think

Not sure why the the front diff would be spinning in 2WD. IWE disengages the wheel from the half-shaft (hence the diff) and the transfer case disengages the front driveshaft from the transmission (hence the front diff). What would be spinning the diff then?The whole point of those two components is so the front drive gear isn't always turning, consuming fuel and causing wear. What am I missing?

 

[obert]

Yes, on many newer F-150s, the front drive shaft does spin in two-wheel drive (2H) due to the design of the Torque-On-Demand transfer case, which has a clutch that causes continuous rotation of the front components, even when they are not actively engaged to drive the wheels. However, if you hear grinding noises, it likely indicates a problem with the Integrated Wheel End (IWE) vacuum system or a malfunctioning axle disconnect actuator, which allows the front wheels to remain disconnected from the spinning drive components.


I have read different opinions on this.

I am not 100% sure but it sounds like it some earlier years are different.

Not saying I am right just quoting different things I have read.

 

[Mac83]

I’m currently dealing with this now on a 23 Platinum that is equipped with 4A. I’ve currently got 55K miles and bought new. I had front differential rebuilt at 23K miles due to a noise in front end. Now, I’m thinking this is all related. Apparently there are no EIWEs on my truck. We found that out when they were going to do TSB for IWEs. I had tech ride with me and there is a noticeable noise and feeling in the gas pedal while under throttle. It usually starts around 50 mph and can be felt under throttle from there. This past weekend, I was up in PA and it’s more noticeable when going up any incline. I received a call yesterday from service department am they told me that the transfer case is coming apart. The sound metal shavings in the fluid. Parts ordered and waiting for them to come in. I’m hoping that this fixed it.

 

[obert]

You have no IWE?

Did not think that was possible with. 4WD F150

 

[Mac83]

That is correct. I’ve been told that some of higher trims, they were eliminated.

 

[obert]

That is correct. I’ve been told that some of higher trims, they were eliminated.

I learned something new to day

For recent model years of the Ford F-150, specifically 2022 and newer, higher trims (Lariat and above) do not use Integrated Wheel Ends (IWEs). Instead, they feature a "Torque On Demand" (TOD) transfer case system where the front hubs are permanently engaged to the half-shafts, and the disconnect happens solely within the transfer case, effectively eliminating the IWE mechanism and its associated potential for vacuum-related failures.

 

[tbeneteau]

So then on these model years (22 and beyond) the front half shafts and driveshaft are spinning all the time which would be the same as a 2021 model with EIWE's with 4A engaged. Everything is connected except at the transfer case?

 

[Mac83]

Update here… received my truck back from the dealer. Transfer case was replaced because they found the noise coming from there and verified with metal flakes in the fluid, which I find interesting because I had that maintenance done literally two weeks before that. Why wasn’t that found during $1600 worth of routine maintenance. Anyway, I was hopeful that this solved my issues. I got the vehicle back and it drove great for a few days. Vibration/scratching feeling in gas pedal came back but not to the magnitude it was at. I also got a new sensation… from a stop, I’m getting a squeak when I hit the gas, it feels like the front diff is shifting or something like that…. It almost feels like a slip. I’m almost to my wits end with this thing. I love the truck and really like Ford… owned a few and I’ve never experienced anything like this. I’m waiting for dealer to call me back…. I’m at 56K miles.

 

[obert]

Wish you the best on this.

I have started to notice a few things with my truck that I will just let it be. Nothing major at this time but things that bother me.

I have been through the wringer with this truck from day one of owning it. I am right there with you and I am at 60k

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