I.W.E. new one clunks when engaging while driving
 

Replaced the driver's side IWE on my 2011 Raptor a week ago.
Old one had a faint clicking, rattling at times while driving.
Turning the wheel or when suspension flexed you could just hear some pretty quiet clicking, like the two ends of the geared splines just touching while rolling.
Everything worked and it was quiet smooth when engaging 4wd, even at highway speeds.
Figured it was a matter of time before it failed and stayed engaged all the time, so I got a new one.
NOW, all seems to work good, quiet when driving in 2wd, OK engaging slow speed 5-10 mph, but...
anything faster and pretty loud clunk slamming sound when engaging.
Wondering if more or less grease needed.
Something I may have missed???
Anyone else had similar situation?
Appreciate any help advice !
THANKS

Wondering if anyone ever had something like this after installing one of their new ones???
Defective part maybe?
Applying and removing vacuum seemed like it does what it is supposed to when installed and at a slow enough speed OK.
BUT, anything over 10-15mph it sounds like it is slamming, clashing, and clunking into engagement :(

Got under the truck again yesterday.
Thought I found something.
The vacuum/vent hose had it's zip tie to the spindle pretty tight.
Thought the vent side might be pinched closed.
Had hopes that may have been causing my issue.
Cut the clip/zip tie and put a new one on looser.
Started the truck and applied and removed the vacuum line a bunch of times.
It was silent going in and out setting still.
Grabbed the cv axle and looked like it was doing everything correctly.
Driving to work this morning, engaged 4wd about 10-15 mph.
Same clunk.
Mentioned what was going on to another Raptor owner a while back, he somewhat jokingly said maybe the other-passenger side.
Repeated 2wd to 4wd a couple times and had that thought.
Going to look at other side closer and see if that is now acting up and making the clunk.

I have no experience with Raptors (I think they’re awesome, especially with the 6.2) but the drivers side is at the end of the vac system, and any small loss of vacuum will cause that one to try and engage first. Had this trouble with my 09, I ended up replacing iwe’s, vac lines, solenoid, and check valve. What exactly solved it, I’m not sure. But the cheapest thing to replace first is the little plastic check valve in the line, and see if it has any rust or dust in it.
Mine had rust in it, so I must’ve cracked a vac line and sucked in some water or something. It doesn’t take much to upset the whole system.

I have been through quite a bit with the IWE's vac systems on a few trucks now.
We had a 2004 Expedition that I had to go through the lines on and repair, also replaced the solenoid.
I had a 2006 Expedition that had to have a couple line repairs.
Now a 2011 Expedition that has had lines replaced and solenoid.
Ran new lines and now both IWEs on the Raptor.
Replaced the passenger side last night.
It had some grindings and shavings in the grease when I got old one out.
Guessing that was my latest noise and issue.
Just strange how it was either quite or I didn't notice it making the noise when engaging before I replaced the driver's side IWE.
Once replaced everything seemed good with truck running in the driveway.
Went around the block and first 6 or shifts between 2 and 4 wheel drive still made a little noise.
Not nearly as bad, but enough to make me wonder and still worry.
A couple more shifts and it was smoother and quiet.
Hoping everything just had to fall into proper place, get grease spread in the right spots, or ? ? ?
Will go for another ride here in a few hours with fingers crossed :)
Appreciate the response and info !!!


OH, and like they say...things went a lot faster doing this the second time

Things seem better now.
A couple more rides.
A bunch more 2wd to 4wd and back and forth.
Drove to Midwest Dirtfest over the weekend and IWEs seem quieter and smoother.