Originally Posted by awq134

Your symptoms sound exactly like mine. does it only happen with light to moderate throttle inputs and goes away as soon as soon as you let off the throttle? Mine is so random, sometimes it will happen a few times in a day, but then will not happen again for a few weeks to a month or so. Maybe I don't fully understand the system, but I'm not completely convinced it's the IWE yet. How/why is it so random? With that said, once I can get some free/ down time i'm going to pull off the front wheels and take a look at them.


My truck has been doing this for the last 2-3 years and the 4x4 still operates normally when selected. I thought about taking it to the dealership, but it's so random that it would be like chasing a ghost.

Originally Posted by robotpepper

Hi all,

Thanks for having me and thanks for taking the time to read this and help! Any and all input is appreciated.

This morning (roughly freezing temperature - nothing out of the ordinary after the brutal winter we just had) got onto the highway to head to work and set the cruise control (as normal) at approx 110km/h (65mph) and after several seconds heard a distinct, quite unpleasant grinding noise. It was loud enough to be heard over the heater and radio. Turned the heater and radio off to listen closer and didn't like the sound of it - sounded like metal on metal. There was no different feel in the floor, pedals or steering wheel. As soon as I turned cruise control off, the noise disappeared! Turned cruise control back on, and the noise returned approx 5 seconds later. If I continued driving along normally and sustained a certain speed, the noise would appear after 5 seconds again and only go away once I lifted off the gas or coasted down a hill... Very bizarre. Once I got to work and poked my head underneath didn't immediately notice anything out of the ordinary - no funny smells or anything...

Hoping someone with a bit more knowledge than I have could provide some insight before I bring it to the dealer and know what I may be getting into...

Background info:
2011 FX4 ecoboost, crew cab. Stock, no modifications. Approx 134,000km (~80,000 miles)

Thanks!

...
It was happening while I was hurrying to work and haven't had a chance to go test it out again - heading out shortly to try and recreate it, as well as test to see if the noise is present in just 2WD or 4WD as well. Posted this problem on several forums and everyone is pointing towards IWE. Still covered by extended warranty so I think I'll drop it off at the dealer and cross my fingers it's covered!

...
Tech @ dealership state they weren't able to replicate noise on highway. Argh. They did note, however, that my brake vacuum pump was being noisy and replaced that under warranty...

Originally Posted by FordServiceCA

No problem, robotpepper. Our Ford-Certified Technicians are in the best position to assist at this time. Have you considered seeking a second opinion at another dealer in your area?

Mariel

Originally Posted by Operator13

I'm very interested in the conclusion you come to. My 2010 made the same noise yesterday very randomly. Keep us posted.