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2011-2014 Ecoboost transfer case problems

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Old Jan 22, 2020 | 07:51 PM
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2011-2014 Ecoboost transfer case problems

I’ve had the loud bang now and then it seams like something is binding up in the drivers front end. My 4wd is silent and everything works fine but now and then there is the loud clunk. Then It goes back to normal. it's defiantly an under a load thing.
Also you'l notice that it happens around 38-48mph 4th or 5th fear depending on the rate of acc. but... not always it's more frequent and repeatable when going up a incline.
I've replaced the IWE's, and replaced them again because one was faulty, replace the IWE solenoid, and check valve. Changed the fluid in front and rear diffs as well as the TC. Noticed no metal.

I bought it used out of warranty but I’m my own mechanic.

im my video I have 4-5 examples. Best heard at 41-43 seconds.
 
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Old Jan 22, 2020 | 09:45 PM
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accelerating / going up a hill ...... these are high throttle positions... That changes the motor vacuum and can effect the IWE... it sounds like an IWE and the change in vacuum is what operates the IWE.......... I would look more at that area... Maybe the hoses themselves have a leak ?
 
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Old Jan 22, 2020 | 10:12 PM
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The TOD transfercase has a worn and slipping cone clutch. Is the noise more prevalent in 4a or 4hi?
 
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Old Jan 23, 2020 | 07:44 AM
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No this idea isn’t correct. The truck is in4H. This means there is no vacuum at all at this point. Only in 2wd there is vacuum to hold the IWE’s back off the hubs. Good thought though.

Originally Posted by steve(ill)
accelerating / going up a hill ...... these are high throttle positions... That changes the motor vacuum and can effect the IWE... it sounds like an IWE and the change in vacuum is what operates the IWE.......... I would look more at that area... Maybe the hoses themselves have a leak ?
 
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Old Jan 23, 2020 | 07:47 AM
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Originally Posted by ford390gashog
The TOD transfercase has a worn and slipping cone clutch. Is the noise more prevalent in 4a or 4hi?
at this point it’s about the same. Now i found this dude who put a camera near his CV axle and. Which makes me think that it’s a CV/ front diff related. There’s no mechanic around me that has steelman chassis ears.
 
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