Front Hub Problems
 

05' Lariat 4x4. I'll keep it simple. Replaced my hubs a month ago, didn't replace IWEs but noticed teeth were worn and had beveled edges. Have never tested 4x4, tested today (in the snow of course) discover front wheels not engaging. CV's are locking in 4x4 and unlocking in 4x2, but wheel freespins under load and creates a sound similar to playing cards in bicycle spokes. Checked solenoid, discovered it was type w/o rainguard, replaced, issue persists. I'm guessing IWE's are too worn and dirty to fully engage with the hub. Posting cause I'd like a second opinion.

Check the vacuum valve on the firewall.

That would be the solenoid I replaced. $25 for piece of mind that it wouldn't go bad.

IWE worn out or leaking vacuum is a good bet... Have you checked the vacuum supply and see if it holds when off ?

Missed that part

I believe everything is working properly, I did do the check with the half shafts going from 4x4 to 4x2 and they worked correctly, so its not the tcase (thank god). I'm still voting on the actual IWEs. When I replaced the hubs, they were very dirty and the teeth were very worn.

Looking at the IWE sticky the worn gears are why I would investigate a stand alone switch to activate the IWE solenoid, or install a separate solenoid and check valve, to engage the hubs before putting it under load.
That's why I speced manual hubs and locked them in before I'm going to need 4x4.
But then I'm a control freak so ....
If when you had it apart and cleaned then lubed the system with 'heavy grease' you screwed yourself, I checked the temp in Va, you're in the teens ~ twentys. I'm guessing it doesn't usually get that cold.

I didn't use heavy grease, just standard general purpose grease around the bearings. Good buddy of mine thinks this truck was a touch abused, probably shifted into 4x4 while the rear tires were spinning a few times. I'm really hoping I haven't ****ed the teeth in the hub

I don't understand what you are saying.

When there is no vacuum applied to the IWE, the half-shaft should be engaged with the hub. If it is not engaged, then the IWE is stripped or frozen.

When vacuum is applied, the IWE should disengage.

Well, I pulled my passenger CV joint off yesterday (it needed replacing anyways) and checked the IWE while I was there. It was filled with dirt and crap and the rubber seal was torn and I could barely move it by hand, so this is definitely my problem.
Ted928. IWE was frozen 50/50, so it just barely engages enough to spin the wheel by hand, but not enough to turn the wheel under a load. I believe the seal was good enough for it to retract, but it was so dirty and damaged it wouldn't engage all the way.

Thanks for clarifying. I went with cheap IWE last spring (there is a thread) and so far so good.

I picked mine up from 1AAuto, should have them installed by Saturday.

There's a good chance that your hub assembly gearing is chewed up as well after "card playing" sound on the wheel hub for a couple days. Check that as well before you install a new actuator and destroy it because the hub gearing is bad, then go back and forth replacing the parts one at a time ad infinitum.