Recurring 4WD Problem
 

I once again am having problems with the 4wd on my 2004 Lariat. I have had the solenoid replaced before (TSB 06-8-15) as well as a front hub and I believe the vacuum line(s). My understanding from other posts is that water drips from the cowl into these lines at the solenoid and causes problems with the solenoid. Is there a TSB to truly fix the problem, or is it a case of I should expect to replace this every year due to poor design?

I'm amazed at how many people have this problem with no recall, I had to have my right hub replaced last year and just had the left one done yesterday b/c of the damn moisture in the vacum lines...the tech suggested I unplug the lines at both ends and blow them out once in a while...sucks!

From what I've read, a replacement solenoid you buy today should have the built in shroud to keep the water off/out.

I have an 04 that I have had for about 6 months and I am afraid to switch on 4wd because of all the problems people have that Ive been reading about on this site...but if you think about it, If I did not read posts on this site I would not be aware that there is a problem and I would have switched on my 4wd by now...so what do i do now?

If you follow the advice others have given, you should engage the 4wd every so often (if you have electronic shift on the fly) to keep the actuator motor exercised and prevent it from sticking when you really do need it.

Give it a shot and see what happens. Start the engine, engage the 4wd, and see if the light comes on. You know the transfer case has shifted at least if the light comes on. Then, go see if you can turn either of the half shafts by hand with the engine still running. If neither turn, you should be good to go. If either does, there's a problem to track down in the IWE system.

+1... part of the problem with my truck is it sits most of the time because it's my 3rd vehicle

Hey VFR_man I ride an 02 R1 most of the spring/summer and fall...YeaH!

You were 100% correct, dealer cost was $16 for a new solenoid which includes a plastic cover built into the bracket.

Just my advice here, is that IF you haven't had any problems yet, either spend the money and get the updated solenoid, or just do what I did and take a small piece of flashing and just fold it over so it covers the top. I actually had mine replaced back in jan 06 and when I got home and raised the hood to take a look, and saw the rain water leaking right onto the top, I had had to make my own fix :-X22
Rich

if this is that big of a deal, then i wonder why ford just hasnt made it a recall? how many have to be replaced before they just say the hell with it and change them all?

My thinking exactly...

WTF! On my way to work this morning and once again I'm getting the grinding noise, this time it seems like it's from my right hub...which was replaced last year! Damn it...I had to drive into work in 4 high again. Back to the dealer...*****!

Dealership replaced the solenoid and a wheel hub once again. Any idea what these repairs would have cost had it not been under warranty? Given the frequency of this repair I am considering a Ford extended service plan. Seems like I am having 4X4 repairs at least twice a year.

Had mine replaced, work was warrantied. They told me approximatley 550.00 to repair both integrated wheel ends.

anyone got a picture of where/how to put homemade flashing over where it leaks?
Mine's not broke so they probably wont give me the upgraded solenoid under warranty.

Yeah, I would like to see that too. I have not had any problems with this. My 4x works fine and always has. I would like to do something to prevent future problems though.