I have a 2004 FX4 Supercrew that is having a problem with the four wheel drive. Intermitently, while driving along in 2wd, the four wheel drive system seems to try and engage itself. It makes a horrible sound like grinding metal (not good I know)!!! If you slow down there will be a loud 'thud' as the system kicks back to normal and then the truck will drive fine for probably about 100 miles or so and then do it again. When it starts to happen, I can engage 4-High and immediately turn back to 2wd and that solves the problem (eliminates slowing down and waiting for the 'thud'). I have taken it to the dealer twice and a transmission and 4x4 'expert' once and everytime they say they can't get it to do it for them so they can't help (of course). Has anyone come across this problem? Any suggestions of components to check that might be causing this? I didn't know if maybe it could be something as simple as a relay or switch?

Any help is greatly appreciated!!!!!!

 

Sounds like a classic... IWE solenoid problem... this thread (and a few more) here...https://www.ford-trucks.com/forums/6...ing-noise.html
should help you in repairing or acquiring the correct parts.

....And Welcome to Ford-Truck Enthusiasts!

 

Thanks for the welcome and the help! I'll check it out!

 

I bought the part today for $47, and it took about 10 minutes to install! Truck is running great! What an easy fix, makes me wonder why the dealer couldn't take care of it...oh well! I appreciate all the help!

 

Very common problem one of my buddies had it happen on his on the way to florida and we brought it to the dealer there, the service advistor said immediately that that was what it was i've ordered the part for mine hope ill get it soon