My 2008 about a year and a half ago would spontaneously make a bad metal on metal grinding noise followed by a gear clunk like it just went into 4wd on its own. It happened a couple of times, took it to the dealer who shrugged. Nothing until now and its back. Any ideas? This is an XL so its a lever for 4wd. Plus I'm right at the end of the extended warranty so hopefully I can get this intermittent problem into Ford's database its the kind of sound you expect to eventually cause a catastrophic failure.

 

"... who shrugged."

And some wonder why dealers get bashed so often and so hard.

Anyway. The problem lies in the 4x4 vacuum system somewhere. (In this case it doesn't matter what trim level or type shifter your truck has) Refer the mechanic or maybe the owner of the dealership to this thread.

https://www.ford-trucks.com/forums/836438-everything-you-wanted-to-know-about-the-iwe-system-and-then-some.html

Ford shop manuals do have procedures for trouble shooting this fairly common issue. The important thing is to have the issue documented at the dealership while still under waranty so you can make THEM fix it. Even if you have to hold their hand and explain how.

 

Excellent. Thats clearly what the problem is (IWE). Thanks. Truck is already at the dealer.

 

Yup. Solenoid on the IWE system. $100 deductible. I've never bought an extended
warranty on a vehicle but in 2008 you could buy F-150's cheap due to the bad economy/auto market so I popped for the 75,000 mile warranty. Glad I did I think, as I also had the cd/radio replaced due to bad cd reader. I say I think because probably none of this would have broke if I hadn't bought the extended warranty

 

Glad to be of service. I wish I'd bought an extended waranty for my wifes (bought new) toyota highlander. What a money pit.