front end noise ,not wheel bearing. not constant. sounds like a rotation grind

Front brake pads worn out.

No. It is a deeper sound.Sounds like a slower rotation than wheel

Front of the engine? Idler pulleys or a water pump? Or is it when you turn the steering wheel...

not engine related. Only when moving. At 20 mph it grinds around 1-2 seconds intervals and speeds up when I go faster

Sounds like it is in the driveshaft. Have the u-joints checked.

IT IS NOT A SQUEAK, IT IS A GRIND

You know, it can only be so many things, just take it into a garage to be looked at or get under there and check it out.

i REPLACED THE WHEEL BEARING AND HAVE BEEN UNDER THERE, THOUGHT YOU COULD GIVE ME OTHER IDEAS

Could the rotors on the front be warped? Pickups are good for warped rotors if lugs are tightened in excess of specs. At highway speed, if you apply the brakes you can usually feel the pulsation of a warped rotor.

it is not the rotors, it sounds like a shaft bearing of some type. slow rotation compared to the speed of the wheels rotation, like it is geared down.

So is the transmission shifting properly?

My 2018 F150 is doing the same thing, started at about 4000km. Sounds like metal on metal, like when you lose a brake pad. It shakes the whole truck. The dealer doesn't know what it is, keep telling me it must be stones between the caliper and the rim. Ford needs to get to the bottom of this, I know of three other 2018's doing the same thing.

We have a 2016 F150. The dealer service guy says Ford are aware of the issue (shaft bearing). We took it in 3 months ago and they greased it, that lasted around 7 weeks. Brought it back in, did it again. Went today and they are now replacing them (but told us the problem will re-occur until Ford figure this out. In my mind, we have been sold a faulty vehicle. I am not happy with having to go to the service shop every 8 weeks and drive a rental vehicle. I'm in shock that this has been a problem (apparently since 2011). Apparently the answer is for a sealed unit (sorry I am not mechanical) but Ford have not come up with the goods?

Thank you I am having the same noise. It is intermittent and really starts up after making a hard left turn. Is this safe to drive?

Guru59PLX Have you had any fix to this issue yet. I just took it to the dealer today and at the end of the day they said they really didn't know what to do. They greased something and cleaned off "excessive brake dust" (bunch of BS) and it still did it pulling away.

I have a 2015 F150 doing the same intermittent low dull grinding sound. Sounds like driver side. I changed the pads with no change in results. I usually hear it while slowing down but occasionally hear it going a steady pace. Never hear it going 35mph+.

Hey guys, this was definitely an issue with the IWE. The dealer ship had my truck a couple different times and didn't come up with a fix. After reading a few posts I took it in again and let them have it for a week. I told them I believe it has something to do with the IWE. It is exactly as you all describe it, grinding when going slow or turning and don't hear it at higher speeds. Also, it goes away when you shift into 4A or 4H 4L. They found that the vaccum line was loose on one side and it seems to have fixed the issue. We will see.

2015 F150 with similar issues. Dealer said to was the rotors were warped. They have now tried to correct three times and it comes and goes. Talked to a different rep at the dealer when leaving. He said it sounds like an common issue with the 4WD actuators. Ford is aware and will fix it but only if you push the issue. I have not had mine back it yet to correct. One note... whenever mine does it the gas mileage falls sharply.

Hub assembly. My front right went bad and the whole rim broke off. Only the caliper was holding the rotor. Changed it out 3 months ago. Now the left side is making the same noise.

I am having the same problem with my 2018 F-150. Limited 4 X4 (2 month old w/3,100 miles) I notice the rotational grinding after my vehicle sits for more than 6 hours. As soon as I put it in drive the noise starts under light acceleration and lasts anywhere from a few moments to a half mile of driving then stops. After reading this thread I am going to take it back to the dealership. Wish I would have read this thread first before dropping $50 G's. If this has been an ongoing problem with this model how did it ever make Truck of The Year???

It should be mandatory for Ford engineers to drive the vehicle for at least 1 year before releasing it for sale....

Looks like I am in the same boat as you all with my 2016 F-150 Lariat (30K miles). I have taken it in twice now. First time they said it was "normal" the second time they said it is was break dust and that they cleaned it - driving away the noise was immediately noticeable. Thinking of taking the issue to Facebook and calling them out! Like GuruYL6Z said, when we pay $50,000 for a truck, we expect simple things like not having it sounds like a wheel is going to fall off when braking

Same problem here. Dealer greased the bearings and no better. Front left. Grinding noise around 15-20 mph. Usually can hear it slowing down.

I had my front driver IWE replaced last week and the problem is gone. Its covered under drive train warrenty under 60k miles. From what I was told, the new IWE is an updated design and shouldn't happen again. A few guys at the dealership said they've changed hundreds of these IWEs in the new models.

After the third visit to Ford the problem is gone!! Of course, it was the IWE like most are mentioning here. If Ford doesn't believe you, switch your truck into 4 wheel for them. The noise will become even more apparent further suggesting they need to replace your IWE. I hope this helps everyone and thanks for the support!

My F150 is doing the same thing, however my Dealer said it was the Wheel Actuator and it was replaced at no charge, 3 months later am getting the same noise

It sounds like different people might be having different problems but I can speak to one. If you have 4wd and are getting a grinding noise clearly coming from around the wheels in 2wd it obviously is part of the IWE system. 9 times out of 10 it starts from a leak in one of the vacuum lines. It is a very cheap fix if you can narrow down where the leak is coming from. If you do not fix it early enough, you will grind down your hubs and have to start replacing more expensive parts. If you do not fix the vacuum leak you will continue with the same noise.

Had a 2015 Ford F150 Lariet 4X4. Changed 3 hubs before 32000 miles and finally a front differential bearing was going out. Traded it in for a 2018. Hope I don't have the same problem.

GuruYK2J4 : I just had the dealer tell me it was a scraped rotor and the brake pad was slightly bent.... got all new brakes and the rotor was “machined” to fix the “divet” that possible was left by a pebble getting in between the rotor and brake pad? My question is, after your IWE was replaced, it is still good to go right? No issues since having it replaced?

@Lucky I am still working through the issue - Replaced the IWE as well as both hubs and vacuum. The noise has gone down considerably but I am still hearing it from time to time. It used to be every time I came to a stop and now it is just at the first stop sign leaving my house in the morning.

Can any of you that have had a dealer confirm they know about the issue, be able to provide the number and name of the person at the dealership you spoke with or dealt with? Maybe they can describe on a professional level what the issue is to my service people?

Just took a tech out with me and he was able to hear a d feel the grinding immediately!! He was a younger kid but knew instantly that it was what I was talking about with the IWE, hose leaks and check valve!! I feel so much better now that it will actually get properly fixed!!

I’m taking my 2015 F150 into Ford tomorrow for the second time... I just got it from them a month ago... wish me luck! Lol.

Have a brand new 2018 F-150 and < 4k miles it just started happening. It's happened the last 2 or 3 times I have left the house. Sounds like a gear grinding noise, in the front somewhere, on the left side. A bit annoyed.

I have the same problem with my 05 f150. I will be driving and the grinding just starts out of nowhere. It’s done it about 3 times now and every time it does it, I pull off the road and while turning I try to hit a bump or something that’ll shake the truck, like pulling into a parking lot and hitting the area where the sidewalk meets the road/pull In area. Anyway, if I hit a bump while turning all of a sudden it’ll make almost a popping noise and then the grinding stops and I get back on the road and keep driving! Haha! Doesn’t sound safe to drive, I know but I can’t figure out what the problem is and everything drives fine besides just the entire fleet of 05 f150’s that ford built are the biggest piece of crap fords ever!

My truck just started doing this last night. I played some you tube videos and the sound is the same for the iwe vacuum issue. Of course i’m Out of state for the weekend on vaca. Is this safe to drive on for a few days??

I have a 2017 F-150 King Ranch $70 k vehicle Noise in front left drivers side and took to 2 dealers

Travelnmomma, you'll be alright to drive. Most people have had this problem for months with no proper fix.

I have a 2010 f150 making the same noise. No idea why but if this is an issue ford knows about why is it not a recall?

I'm having same issue. Got under it took the skid plate off looks like where the CV axle goes into the front diff is leaking fluid, seems like the seal busted and probably the bearings are the grinding sound were hearing mines a 2013 f150

I just recently started hearing a sound in my truck at 75mph+ Kinda strange, below 75 wasn't a problem. I found this video on YouTube and it demonstrates the sound almost exactly. I'm not sure if it's what you all are hearing though but it should be a quick fix. I'm going to wait till tomorrow morning to get under the truck so I don't burn the shit out of myself but hopefully this helps. https://youtu.be/x9m4KzzqSaE

I found a cracked vacuum line right where it plugs into the solenoid. Hopefully that does it. Check all your vacuum lines!

Hi. I have a 2010 f150 xtr. I think I have the same problem. Is this what it sounds like? https://www.youtube.com/watch?v=RWKAZ091Csk&feature=youtu.be and did anyone find a solution?. Is it a loose brake pad?

2018 XLT - 9.5k miles, been doing it mostly cold and exiting a corner. Lasts during acceleration until you let off the gas. Noise sounds similar as if exhaust pipe falling off in front dragging into the pavement. Scares the crap out of occupants. Dealer says heat shield issue. I drove off the lot and it did it again on my first turn onto the dealer’s street. I ask if anyone Google’d the issue and they laughed at me!

I had my iwe replaced 9 months ago on both sides of my 2014 f150. Now I get a noise and vibration like the truck is pushing the front tires against there will. Happens whenever it feels like it. Almost always happens when I get on the gas to enter the highway. Switch it to 4x4 and problem goes away. Could happen again in a minute, not at all for the rest of the 1 hr trip, or 10 more times. I have asked a few people and nobody has a clue. It has had a new vacuum actuator twice and been vacuum tested and it says it's fine. No clue where to turn and don't have money to take to the dealer.

Dealership is fixing mine now after I insisted they Google the problem and watch YouTube videos. Turns out there are three "TSB"s (service bulletins?) from Ford on the matter. Usually has to do with a vacuum problem so they are replacing some vacuum switch near the hub on the front wheel(s?). Interesting video on YouTube goes into great detail on how a failing vacuum pressure makes the gears grind but not engage 4x4. Also has to do with IWE(?) thing in the hub as well, which is the 4x4 engaging gears, I think. Over my head, but I hope to get my truck back tomorrow! :-)

Lmk how it goes and what they say.

It’s the abs system that has the 3 little 8mm bolts behind the hub.. it’s a spring/air assisted system if you take it apart you will notice a gear like ring on the hub and on the axle and on the actual abs module.. what happens is the abs module is usually always supposed to be locked into the gear side of the hub..and only when you brake hard it’s supposed to switch over to the axle gear in order to help you brake but the problem with these trucks is that the abs module fails and the abs starts to go over to the axle side of the gear like ring and that’s when you hear the grinding noise!!! So as of now I’m trying to find a way to fix it!! I’ll let you guys knoww

I have me F150 2003 V8 when I am driving I can hear something loose under there so I grabbed my tire and my tire shakes also when I took the tire off I was checking out the caliper and the rotor and I notice the rotor you can move back and forth could you please help me and tell me what the problem is do I need to replace the hub bearings or it's got something to do with the rotor when I go break the truck stops hard also when it stops it don't want to go forward I know it's not the brakes

i had the same problem on 1 2013 and 1 2015 f150 4x4 well the customer came in to my shop both complain that they had a brake problem well took wheels of done 4 wheel brake job both trucks the next day but different times like a month apart well they came bake with the same noise y'll are talking about well put the rotors back on my hunter brake lay and found that on one side it cut prefect and the other ruff not bad but just enough you could see with a light but not the on the lay. so on one of the trucks i recut the rotors same thing so got the truck back in the shop put them back on the lay took 320 sand paper held on both sides till they where as smooth as a babys butt sent them down the road and both was quiet as a mouse. both customers called and said well done. maybe that will help y'll out.

I have a 2011 Ford f150 King ranch and hear a grinding noise . I took it to the delaer and they say it's nothing wrong with it but the noise comes and goes all the time.Has anyone any idea of what this is and who can fix it??

If it is from the wheels it is because the Auto-Locking Hub Actuator have lost their seal and collected a bunch of water. I just recently replaced them on my f-150 and it solved the problem. It was an easyish repair. This is what you need just find your correct model/make and year. Check the vacuum solenoid to see if water is leaking onto it. It is either on the right or left side under the hood directly up against the firewall. Make sure no water is draining on to it. If it is getting water on it use some sort of material that is waterproof and make a housing for it that will deflect any draining water. https://www.1aauto.com/auto-locking-hub-actuator/i/1ashs00588? f=597225&y=2005&utm_campaign=gb_csv_br&utm_content=SHS&gclid=Cj0KC QiA2o_fBRC8ARIsAIOyQ-ldI8rNo9uerct-CwgJcbeblMEW335oZYmofVI_5I- 9jHJi_9uWIR4aAga9EALw_wcB hope this helps. lmk if this solved it. And most of the people in this thread that has the same problem this should fix it if you replace those parts.

FIXED THE PROBLEM FOR ME! Dealership replaced the vacuum thingy (switch?) that services the 4x4 engagement process and it has been perfect ever since. Way easier than all these other potential solutions. It's a vacuum problem that lets the 4x4 gears slip into place, but not all the way, which causes the grinding. New vacuum part and it's all good to go!

the same thing has been happening to us. I have had it into the dealer 4 times and now they tell me there is nothing wrong and the sound won't hurt anything. Just fricken fix it, that's all I want. If you had a fix it wont last long, everything that has been mentioned has been done to my truck and within 2 months the sound is back. very frustrating

I have a 2012 Explorer making the grinding noise when i brake. Took to mechanic and he said that all brakes were fine. Does this IWE or ABS issue apply to a 2WD vehicle or is it only on 4WD?

Had been experiencing a grinding noise on the drivers side for a a bit. Began happening after new tires, maybe coincidental. Sounded like an expensive issue. After reading through the posts, I decided to begin with replacing the vacuum check valve. Went to the local dealership and cost me $10.40. Took 5 minutes to replace and it worked!!!! Thanks.

Everyone claims they have the same problem, but you’re actually all chatting about slightly similar different problems. To clear up the all the 13th generation F150 issues alot of you new owners think you have, read into the Borg Warner variable torque on demand (TOD) transfer case your truck came equipped with. Lariat and higher model F150’s which are mostly all equipped with 4A are programed to engage the IWE’s even when the truck is in 2H for the first several miles after any cold start. It’s an embedded strategy programmed in the frimware so that if you need to select 4A at highway speed for any reason the truck can do it confidently incase if any internals had become ceased. It’s suposedly a precautionary measure Ford engineers implemented to cause less metal fatigue in the transfer case, instead it wears down your IWE’s. I’m not saying one method is better than the other. Owners in cold weather states will notice it more than others. If your brand new F150 is sounding like the IWE’s are engaging when 2H is selected and if you own a Lariat or higher trim package that’s because it is. Ford programmed your 2015 or newer F150 to do that and it’s normal. There’s no need to make countless dealership trips and blame Ford engineering or assembly workers. It’s unfortunate Ford dealers don’t tell owners this upon purchase, but most dealerships have no clue. Heck, you’d be lucky enough in my area just to find a sales person who knows what an FX4 package is.

I'm having the same problem with my 2014 F150. 3400 miles. Grinding sound coming from the front end, maybe left, usually stops after about thirty seconds or if I shift to 4X4. Taking it to the dealership tomorrow. Happens about every other day and does seem to happen so far only on freezing mornings.

I have a similar problem with my 2016 4x4 with 60,000 miles. My noise occurs around 35 - 40 mph as well as at slow speeds in A4. Dealers suspects it is the vacuum actuators for the front drive. Loss of vacuum causes the partial or failed engagement of the front drive axles. Also will be replacing the axle bearings as recommended when changing the front actuators. Let you know next week how it turns out.

Chad above, thanks for the update. No dealer has a clue what to do about it. I had the brakes replaced and the IWE completely replaced due to this rubbing/grinding noise. Has not helped and been back multiple times. I think I am going to trade it in. It is annoying as hell. Anybody interested in a 2016 Lariat? Gorgeous truck, but not happy.

Check the vacuum switch connected to the IWE. That's what mine was and it fixed it perfectly!

it is a vacuum leak in the line leading to the 4wheel accuator behind the hub. The vacuum line gets a slight leak that only leaks when pulled tight when turning. It causes the 4wheel system to stay half engaged. The vacuum suction is what pulls the acuator out away from the hub to allow the truck to roll in 2 wheel. It will make the sound you are talking about, make it seem like it shifts funny, and rob you of gas mileage. Simple fix tho, if you are not replacing the accuator and hub assembly because you have allowed it to happen to long, you just simply replace the vacuum lines. I did mine custom and made sure to allow more room and protective layers wear needed to avoid future leaks. Hope this helps.

I have a 2018 F150 4WD and I am experiencing the same issue. Found out it's my entire 4WD system went bad in the front end after using it for the first time.

Quick update - I have now had my truck in for the 7th time. Replaced the a solenoid, check valve, and vacuum line none of which have fixed the problem. They will now be replacing the wheel bearings at a cost of approximately $700 a side. I have spoken to several techs and they have all confirmed that this is a known issues which is why I am now working with Ford Corporate to get things resolved.

I have 2017 f150 4x4. Mine is making the sound and it sounds like a muffler dragging in front driver side. It can be heard away from truck to, which I thought maybe could only be heard inside cab. I left high school baseball field last week and it started the sound and scared all the players outside. It usually does it when I turn wheels to the right.

Recently just had the brakes and rotors put on my 2015 F-150 Lariat. The day the work was completed a whoop, whoop, whoop noise occurs when braking at slower speeds. When turning the vehicle at intersections a grinding metal to metal noise appears every so often. I've taken it to the dealership twice now. The first time they diagnosed a bent rear backing plate. I insisted the noise was coming from the front of the truck. I just returned from the dealership today and was informed they believe it is my front wheel bearings. Reading through this thread, I am not convinced it is a wheel bearing issue. The truck drives great besides this and has no other issues in 2H or 4A. Any suggetions?

If it's a horrible grinding noise, make them check the vacuum switch and lines to the thing that engages the 4x4 drive. That was my issue and it's never done it again. They don't know how to use (and refuse to try using) Google to see that was the issue.

I have a brand new fully loaded (every option available) 2018 F150 Lariat with 2.7eco (built Oct 2018) Purchased in December. First ride from the dealer with 65 miles on the odometer started hearing a thumping (thump-thump-thump) noise between 25mph and 35mph. Dealer said flat spots on the tires. Truck has been in 4 times to dealer, replaced one tire and rotated the rest. Does not matter how much driving I do. Thumping noise is there. Notice it more when outside temp is below 30. Also noise is louder when engaging the 4x4 vs keeping it in 2wd. Noise is coming from the front end. Truck just broke 3,000 miles. Dealer has no idea. First claimed that it was a common / normal noise with the F150 and just keep driving that it will go away. It will be back in soon.

I live in the UK and at the end of 2018 I bought a brand new 3.2 Ranger with 16miles on the clock. At 460 miles, I too started to experience the same noises you folks are describing at low speed braking. So far, in the 6 weeks of owning the truck, it has spent 2 weeks in total at the dealership ramps, and still no fix. I have been told its brakes, drive shafts, transfer box, and latest, front auto hub locks not fully disengaging in 2H. A recent dealer update is, it could be at the dealership for a further 2 weeks before replacement parts arrive from Germany! This issue appears to be present in the Ranger series too!

Just took mine back to the dealership for the same noise however the first time they replace the IWE but the problem was still there notice as I pulled out of the dealership. I told the dealership that I did not want the truck back until it was fix the correct way. My noise now does it in 2x4 and 4x4. 50+ K for pricing I expect better quality then this.

2013 f150 lariat 5.0 just started about a week ago. Only when breaking from speed between 20 and 5 mph. Never on accel. Any resolutions? I can't even tell it's coming from the front or the rear.

2013 f150 lariat 5.0 just started about a week ago. Only when breaking from speed between 20 and 5 mph. Never on accel. Any resolutions? I can't even tell it's coming from the front or the rear.

I have a 2013 Ford Expedition Limited EL with the 2H 4A 4H 4L Borg Warner Transfer case. I have had an Axle bearing type noise radiating from the Left Front since I bought it around 43k in 2018 (currently under 46k). The Noise is the same with 2H 4A 4H positions.I have replaced the Left Hub Assembly 3 times (Right Side once), Cleaned and vacuum tested Both Front Actuators, Replaced Left Axle Shaft Assembly, Installed New Rotors and Pads, and still the same Axle Bearing Noise that starts around 10 mph and gets quiet around 70mph plus. (Noise was originally noticeable from maybe 35 mph to 55 mph). I went to a privately-owned auto shop earlier today and they diagnosed this as a Bad Front Differential. They are currently working up estimates to either repair or replace. I wanted to Note the shop had the Expedition on a lift and placed a Stethoscope in different areas to verify problem and also showed me a sample of the Front Differential Fluid which was Light Grey-Colored-- which they said was also a Bad Sign (It did not look Metallicy). Also to Note, when on the Lift, even when in 2H, the front wheels would be turning with the rear wheels. To me it looked (also) like the transfer case motor was not Disengaging the front Differential, but the mechanic and shop owner said there is fluid movement in the transfer case that causes the front driveshaft-and- Differential to turn all the time--even in 2H (I will call this Fluid Propulsion). They said they saw this in an Astro AWD van a couple weeks ago (Astro is All-Time AWD -- I Don't see how this can compare). Anyway, I have read a lot of online threads from people with the front howl/axle bearing sound and thought this might help someone, or perhaps my current shop is wrong on the Differential Diagnosis and/or Transfer Case "Fluid Propulsion" statements. I do know there is a difference in the operation of Transfer Cases on F150's and Expeditions that have the 4A option, and the internal clutch system contained within.

If you're having noise coming from the front end at low speeds it is likely the 4wd actuator. I just changed mine in my 2013 F150. It cost me about 30 bucks and there is a YouTube video showing how to do it. It is super easy and took me about 5 minutes. Worth a shot.

Thanks for the response, but like I said, I removed, Cleaned and tested the Actuators. Noise is Definitely the Front Differential--3 shops have had it on a lift now and one even let me listen with a Stethoscope. I'm mostly trying to figure out why the front Driveshaft-Differential-Axle Shafts (Actuators Dissengaged from Hubs) in 2 Wheel Drive Does Not Dissengage. I can't imagine No-Load on Front Differential is a good thing. Front Differentials on Fords WITHOUT 4-Auto Do NOT Spin when in 2 wheel drive.

I have a 2018 F150 and the same issue, grinding loud sound drivers side front. Of course it wouldn't do it for the Ford service team. Low speeds, if I spent on the gas it's louder. Then I spots.

Is the 2018 F150 a Limited or King Ranch with the 4 mode selector on the dash to engage the 4x4?

2015 Lariat, same bearing thumping sound from front diff for me. Replaced IWE’s more than once, new solenoid, new check valve and new vacuum lines. Replaced driver side wheel assembly (bearing and abs sensor). Changed front diff oil, no discoloring and looked good. Noise still there. My abs light has been coming on intermittently. Next I’m changing the passenger side wheel assembly (bearing and abs sensor). If that doesn’t take care of the problem I would have to say that I’ll be rebuilding the front diff. Very frustrating Ford. Please sole this problem.

Ford finally resolved my front end problem - hubs / IWEs / actuators / vacuum lines / check valves / tires, etc were replaced by the dealer. Then Ford sent in an engineer to diagnose the problem. They replace the complete differential axle assembly unit. Issue resolved. My advice is to read up on your State's Lemon laws, and take audio-videos of the issue. Nothing against the dealer techs but they make money by turning in as many jobs as possible. Good Luck.

So today after pretty much giving up on trying to self-diagnose the problem of the grinding noise, I reached out to a Ford mechanic on the app Just Answers. I explained that I have changed out the brake pads (3 times), rotors (twice), calipers on each front wheel, the hub assemblies, on the front wheels, and I still have a grinding noise at low speeds. (less than 20mph). He pulled up a bulletin from Ford, that explained that the Planet Gear Assembly and the Rear Ring could be the culprit, so it is all transmission related. I was actually thinking this today. Gold star for me, but I was thinking I needed a transmission flush, so maybe not a gold star per say. So I am going to reach out to a transmission shop tomorrow and see if they have knowledge of this. The bulletin says if for XL and XLT trucks and I have a 2015 F150 Lariat FX4, but I assume if we have the same transmission, it could be the same problem. I was thinking the IWE's as well for the longest, I even changed out the solenoid and the check valve, I can go into 4 wheel drive and the grinding still persists. So I think that throws out the IWE and any vacuum related issues. Thoughts????

This is the bulletin that I was sent via a Ford mechanic: 45452 2015 F-150 XL And Or XLT Vehicles Equipped With An Electronic Shift-On-The-Fly (ESOF) Transfer Case - Rotational Noise - Built On Or Before 6/16/2015 Some 2015 F-150 XL and or XLT vehicles equipped with an ESOF transfer case, built on or before 6/16/2015, may exhibit a rotational noise from the transfer case while in 2-wheel high (2H) that does not change significantly when shifted to 4-wheel high (4H). The noise can be described as ticking, scraping or rubbing noise that occurs between 32 Km/h (20 MPH) to 80 Km/h (50 MPH). The noise is most noticeable at lower speeds and will increase frequency with speed. To eliminate this concern, replace the Front Planet Carrier (7A398) and Ring Rear (7A153). Refer to WSM, Section 308-07. Use applicable labor operations from Section 7 of theSLTS manual.

wscottparks, The Ford mechanic on the app is referring to the ring and pinion gear in your front differential - not the transmission. It is possible the front differential could be the same on an XL, XLT, limited, Platinum, king ranch, but the Transfer Case is different below the limited model. The Limited and above models have what is called a 4 mode transfer case where there is a 4 Auto feature. The Lesser models do not have the 4 Auto feature and are considered 3 mode. The front differential noise(usually sound from left front) usually occurs on the 4 mode F-150s or expeditions. Most likely has to do with 4 mode causing the front differential to free Spin all the time versus just part of the time-- even continuous in 2H--not just the first few miles and not just when cold outside. This is the part where I can't get anyone from Ford to be in agreement on whether or not it's supposed to spin all the time or just part time. But mine spins all the time.

After further review, I am also thinking the universal U joints may need to be replaced. I did some reading and video watching and the symptoms seem to be in line with my truck. Grind at low speeds, then runs great after a certain speed. So I’m going to get under the truck and see if there is any play with the drive shaft.

TallFordGuy, did you ever get your noise resolved? I just bought a 2013 Expedition Limited and it has a light humming sound in the left front from about 20-50 mph. It’s most noticeable at about 42 mph. I’ve also noticed that it’s more pronounced with just a little left steering input. I’ve already replaced the left front wheel bearing assembly and verified that front hub actuators are disengaging in 2WD.

i have a 2016 F150 same grinding issue. Dealer found metal shavings in from differential. I will need to replace or rebuild differential. F150 has 64k miles and is not covered under warranty. No assurances that rebuild will last any longer or as long.

Guru1TQ2R, Is your 2016 F150 a limited, platinum, or Eddie Bauer with a four mode selector for the 4 wheel drive on the dash? I have a solution to avoid this problem in the future, but I need to confirm this first. Thank you

Marco that is not abs. That is the 4 wheel drive servo. When you flip switch on dash to 4 wheel drive vacuum is sent to that thing that engages the 4 wheel drive. Different from the old lock out hubs we had to do to get 4 wheel drive. But this will cause a racket when toast. Around 65 to 70 bucks for part online.

Try brake sheild it sits behind the rotor i took mine off and have not heard it yet but mine is a 98 f150

I have a 2018 F150 Raptor. 60,000 miles Started out squeaking, then grinding and pulling all over the place. I delayed calling the dealer because I'm stupid ! LOL Finally called and they couldn't get me in for 2 weeks. It got so bad that the bolt from the lower ball joint wore a groove into the rim and tire. According to the dealer, the wheel bearing went and because I waited so long it damaged the 4 wheel drive. I have a premium extended warrenty but the dealer says they can't use it because I never should have continued driving. I'm so screwed. BUT..... if this is a known issue like everyone above says, shouldn't they cover me? Is it worth pushing the issue or will it just lead to aggravation and no results?

fords are known for having bad iwe gears in them ford knows this but has never made a recall for them this started in the late 80's if i remember right . i have a 2013 f150 4x4 it will do the same thing you are describing but if i put in 4 wheel it stops right away. sounds like a grinding in it .mine is coming fromt he left front side. also they are known for the abs module going bad on them which can cause the same effect or the abs sensor will also cause this . took mine several times to the dealer no answers couldnt figure it out . got ahold of a mechanic thats worked on fords for 50 years and he told me about it . replaced the iwe gear on the left side and sure enough the problem is gone . ford doesnt want to make a recall on this cause they would have recalls as far back to the 80' on trucks that are still on the road . lot of money to be lost there . so until they ever decide to fix this problem it will remain even the new ones have the same problem not all but quite a few

Speedometer cable

Maybe Speedometer Cable. My speed cable makes a grind noise.

Change the check valve in the IWE vacuum system. It's up by the brake booster. There is an updated valve and it cured mine immediately after a month of chasing my tail.

Mine does exactly what you guys described. It is knocking noise when going slow or turning and don't hear it at higher speeds. Also, it goes away when you shift into 4A or 4H 4L. Just for grins we turned into a 2wd truck and removed the front drive shaft. The noise completely went away by doing this. I have no clue if this helps anyone narrow it down some or not. It was just nice to not have that knocking sound for a while. The transfer case was replaced. The front actuators were replaced. New 4wd vacuum control solenoid. And of course it is still doing it. We even stuck a gopro underneath and drove it around. It looked like when we heard the nocking noise the 4wd was engaging and disengaging. This will really make it hard for me to get a Ford again. I know all trucks have there issues, but I'm ready to take my chances with another one after this mess.

So ive been having issues with my 2016 F150 XL FX4. ive replaced the wheel hub on both sides and i noticed that my 4x4 stays engaged even after i start the truck but once i put it in 4x4 and back in 2x4 it stays in 2x4 until i shut it off then i do the same thing again but i noticed all of this to late and now my 4x4 diff sounds like its grinding on the drivers side has anyone ells had this issue

mine also stays in 4×4 after switching back to 2x4. i turn it to 2x4 then back up (6-8 feet) until it disengages. i can hear a slight clunking noise when its out of 4x4. i havent had any grinding noises from the differential so far.

Ok so ive been working on the diag on the 4x4 staying engaged even after i start it. I used a vacuum testing kit and test every line i could think of the check valve and cylinoide and even unplugged the cylinoide and the vacuum system has started to work again so if you are having this issue i would jack up the front and i would pull the vacuum line off the cylinoide and use the tester on the line the feeds your iwe and spin the wheels to see if your 4x4 is disengaged if it is your cylinoide and check valve are more then likely bad if it still stays engaged your iwe might be bad i hope this helps some of you it might save you some diag fees because the dealer told me nothing was wrong that they could find and still charged me 300 for the 3 hours they spent on it

100% IWE vacuum system. Once they wear down, they lose suction causing slight connection in your 4x4 mechanisms. I had mine replaced towards the end of winter which fixed it. Just have to convince ford dealer to do it. Unfortunately 7 months later I’m hearing a clicking noise from the same spot, rather than the rub noise that was previously fixed.

It’s the cv joint

So if your IWE fails and you dont catch it soon enough. Yes the cv axle will start to fail and you can start tracing damage back to your 4x4 front diff as well because of all the excess vibration and over use of the bearings in the diff because the 4x4 should never be used at high speeds. Ive got my truck back on the road again and it drives great.

For me it was an idler pulley . Took it to shop they couldn't find the problem? Thought it was wheel bearing. Brought the truck home gave the idler pulley a shot of liquid wrench problem solved? Changing it tho. Maybe some of the Ford boys could use this one. Only on left turns it made the weird rotational grinding noise. Anyhow that's a cheap fix. Better than 400 bucks for a wheel bearing.If your brakes and wheel bearings are good it's worth a try.

Well if the idler pulley is bad you wont feel the vibration in the front end. sound and feeling can make a drastic difference in diag if you have front end noise without any vibration your problem may be contained to to the engine or something attached to the frame because vibration in the steering wheel and noise from the front end is more than likely a drive train or suspension issue

I own a 2016 XLT. About a month ago I had my tires rotated along with the oil change. A few days after I started to hear a noise that sounded like metal on metal. I put the front end in the air with my lift and rotated my drivers side front tire. I could clearly hear the noise and understood that it was coming from the bearing. I had to drive an hour that day north to pick something up and on the way back the noise got to be extremely loud. I pulled over into a gas station to see my front left tire sitting at an angle. (Almost like a Razors front tires). I had it towed back to the shop and caught a ride home. It sat there for about four days and they ended up replacing everything in the front end of the left side. Now a month later, I was headed home from work and just got to the bottom of this holler trying to get to the top of the other side when I started to hear a high pitched metal scraping noise, Sort of like what I had heard before. I could not go more than about 20 mph and could barely press into the gas without hearing the noise. I got it to the shop (barely). Its been there over a week and what the mechanic told me is that, "He has absolutely no idea of whats going on with it." When he would put it into four wheel drive the noise would quit all together. Take it back out of four wheel drive and it would start up again. He has already replaced the vacuum hose to the part that controls the switch between 2 and 4 wd. He replaced the whole electronic differential locking thingy. Do y'all think this could be the issue? Or maybe something in the transfer case? Because this seems to be the same issue a lot of you have had. If anybody knows the answer help a fellow ford owner out please.

It's in your transfer case most likely

Your front differential needs to be rebuilt

I would like to throw my experience into this discussion. I bought a 2015 F150 4x4 brand new in 2015. We have not had any real issues until the last couple of years when we started to hear a slight grinding in the front end. I am certain that we had pointed this out when we had taken the vehicle in for service and it could never be replicated and the dealership told us that they could not offer a solution. Well now that the warranty is expired, they have miraculously been able to quickly identify that there is an issue with the 4x4 components and we now have to replace both wheel hubs and the IWEs as well as the vacuum hose components. Of course this is now at my cost and they will not accept any responsibility. I am now seeing many posts about this particular topic and how it seems that the service department cannot find a solution to this grinding noise before the warranty expires!

You go get tires rotated and what happens alot is the rim gets stuck on the front hub from corrosion and the mechanics take a sledge hammer to the tire and wack it from the back to free the tire off the hub It messes up the IWE seen it several times and read it on line.

Sometimes the noise might be due to the freeking hub trying to engage the axle most like due to not enough vacuum pressure. Might want to check for leaks on the vacuum lines to the IWE ... This is easy to do. If it doesn't hold pressure... You might want to check the IWE themselves. IF everything checks with the vacuum line to the IWE. Check the Check Valve (It is suppose be a one way valve. Let's vacuum in but not out (Hope you know what I mean). There is also a solenoid that let's vacuum to the IWE when the car is in 2H ... (I think it's stupid that vacuum has to be on all the time to pull back the gears that allow the shaft to engage). The last think .... check the vacuum pressure coming from the engine (Some is a vacuum pump and some is a series of hoses that provides the vacuum). That can go up and down as you drive -- that's why there is a vacuum reservoir -- but if you look any amount of vacuum, it will cause the axle to try to engage and makes a horrible grinding noise. Here is the just of it. 1. IWE busted 2. Leak in the Vacuum hoses 3. Check Valve or solenoid 4. Vacuum provider not providing enough