I have an 05 4x4 F-150 that intermittently makes a sound like a piece of metal is dragging from the front end. Have taken to dealership several times and they cannot reproduce or find anything wrong. It has happened about 7 times in a year so very intermittent. It continues until you slow down to about under 10 mph. Extremely loud. I have taken to a couple different dealerships and they have no clue. Any help would be greatly appreciated.

 

Could be the problem with the 4x4 solenoid. Take this TSB to your dealer.



TSB 06-8-15

05/01/06
INTERMITTENT IWE NOISE, 4WDH LIGHT AND/OR
4X4 SYSTEM INOPERATIVE, DTCS - C1979 AND
C1980

FORD:
2004-2006 F-150

LINCOLN:
2006 Mark LT

ISSUE
Some 2004-2006 F-150 and 2006 Mark LT 4X4 vehicles built before 4/24/2006 may exhibit a noise in 2 wheel drive from the front Integrated Wheel Ends (IWE) and/or the 4X4 system being inoperative. The IWE solenoid may have ingested water and passed it to the IWE system causing water contamination in the vacuum portion of the system. A shorted IWE solenoid can set the codes C1979 and C1980. If either code is present, the 4WDH light will be inoperative.

ACTION
Use the following Service Procedure to check and repair the 4X4 system.

SERVICE PROCEDURE
1. Replace the IWE solenoid. Torque the new design bracket and solenoid to 62 lb-in (7 N.m). It will be necessary to remove the vacuum lines from each IWE down at the wheels to check for water being present.

a. If no water is present at the vacuum line at the IWE, install the new solenoid with bracket. Reconnect all vacuum hoses.

b. If water is present allow it to drain from the vacuum lines. Then follow the updated procedure outlined in 2006 Workshop Manual (WSM) on-line version, Section 308-07A, Pin Point Tests B21 and B22. These tests checks IWE leak rates with vacuum and will remove any residual water from the IWE. Reconnect all vacuum hoses.

2. If the IWE looses vacuum quicker than specification. Refer to WSM, Section 204-01B for normal diagnostic procedures.



Parts Block

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage

OPERATION DESCRIPTION TIME

060815A 2004-2006 F-150 4X4 and 0.5 Hr.
2006 Mark LT 4X4: Check
Diagnostic Trouble Codes
And Replace The IWE
Solenoid (Includes Time
To Check For Water At
The Wheels) (Do Not Use
With 12650D)

MT060815 Claim Additional Labor Actual
Required As Actual Time Time
Or Use SLIS Operation If
Available

DEALER CODING

CONDITION
BASIC PART NO. CODE
9E441 42

 

Yup, it's either the IWE solenoid of the hub itself.

 

Thanks! I will take this to them today.

 

Next time its doing it, pop it in 4wd, see if it still does it. Willing to bet, its the vaccum solenoid ingested water.

 

Don't forget to give us an update please! Good luck!

 

96f150: Did you know Ford incorperated your idea of a "splash gaurd" for the new IWE solenoid units? Got a third one installed on my truck today and it comes with a plate over top of it.

 

Darn I should have got a patent on it!! . I guess it takes them having to replace a thousand of these solenoids, to have an engineer look into a fix for it.....Anyhow, hope that works for ya

 

96F150 was that a 'how-to' you guys are talking about? I can't find it. Can you link it please? Thanks!

 

I was just reading this thread, and even though it's a little old, I thought I'd ask anyway.
I have an 04 F-150 XL 4X4 V-6, with a very similar problem. It has a metalic grinding kind of sound that I think is coming from the transmission. It doesn't matter what the outside temp is, the noise is still there. Kind of sounds like a piece of sheet metal up against a grinding wheel.
I hear it up until the trans shifts into overdrive, then it stops. When the trans downshifts, it comes back.
I've had it to the dealer numerous times, and they can't figure it out.
The trans shifts properly, but the noise just won't go away until overdrive kicks in.

 

Just like to say i found this thread and performed tsb testing suggested by sgt82nd due to me having the same complaint as marleyz. althought i have no idea what an IWE solenoid is and my local dealer not having a clue, did find that the thermactic air control solenoid for the front hubs were intermitently working. this was causing the hubs to try and ingauge while driving causing a loud metal grinding sound coming from the front of the vehicle. ford does have a part # for an IWE solenoid which is givin to us by sgt82nd but has no idea of the location of where this item is or even a description of what type of vehicle it belongs too. i spoke with many different dealers and the closest location i could get was too follow the vacuum lines at the right wheel upto this IWE solenoid. which we did and it came to part # e8ae-9h465-ba which is called a thermatic air control solenoid. so i dont know if all the listed vehicle are equipped with a IWE or if this thermatic air control solenoid is the samething. although the part # are different along with the prices. all in all with out this forum and the help of the few that replied problem was found and repair was made. id like to say thanks. wait what about this splash shield or guard that 4doorsr and 96f150 are talking about, do i need this or does it apply to the part i found defective. the solenoid i replaced is near a rain drain and may get wet??????? if any one knows please post.

 

The IWE solenoid is mounted to the firewall, right behind the battery. The solenoid # i have is 6L3Z-9H465-B. This number may have been updated again Sep 06. I made a shield cover for mine out a piece of flashing that I just jammed in there....kinda puts a little roof over the solenoid! I have stil have to put a pic up in my gallery.
Rich

 

By the way...I took the truck in and referenced TSB 06-8-15. They made the repair and I have not had the problem again. Thanks so much and sorry it took so long to update. Once again, Thanks!