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2005 F-150 4x4 with 220k on the clock. Lately, when we start the truck and take off down the road in the mornings there is an awful grinding noise coming from the front end. If I turn the transfer case selector to 4-High the noise immediately goes away. If I then switch back to 2-High the noise usually will not come back until the next time we start the truck.
Does this sound like the module on the firewall near the battery? I don't see any vacuum lines disconnected around the axles.
You can try an IWE solenoid that is mounted on the firewall behind the battery, especially if it is not the new version with the built in hood to protect it from the rain/water. You will need a vacuum pump to troubleshoot further.
As Techrep mentioned, there is an updated version of the IWE.
The design of the cowl tends to direct water on the passenger's side to drip right on top of the solenoid & can lead to water damage or getting inside causing partial engagement.
The newer IWE has a cover over the solenoid as the previous poster mentioned.