Metallic front end rattle issue.

I have a metallic sounding rattle coming from the front drivers side of the truck. It happens when the suspension cycles quickly over small bumps and its progressively getting louder and worse. I ruled out the sway bar end links by disconnecting the sway bar, the brakes seem nice and tight, there isnt any grinding or issues when the front tires are in the air and the tires are rotated, and the only place I can find any metallic rattle noise is when I hit the front axle with a rubber mallet. Any ideas?

Here is a quick video, listen for the metallic rattle. WIND NOISE WARNING

I hate to even hazard a guess because even with the video it would be a completely uneducated guess.

I watched several times, but I’m not able to pick anything out. I hear the rattle, from about 9 seconds in to the end.

Why is your Axel spinning? If your in 2wd it should be stationary. I'm guessing you blew a iwe or a vacuum line


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Huck said:

Why is your Axel spinning? If your in 2wd it should be stationary. I'm guessing you blew a iwe or a vacuum line


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I always thought your front axles will always spin no matter what youre in and all the 4hi/4lo magic happens inside the transfer case when things engage/disengage...

Hopefully I can get it to the dealer this week for them to see what they can do, I just like to start narrowing shit down before I take it in so they dont waste time.

edit: My assumptions on the IWE system were wrong, thanks Huck. I come from the AWD or solid front axle world so the whole IWE system is new to me.

Your incorrect. the hubs unlock at the wheels and the transfer case disengages. That's the whole point of the IWE system.
With everything disengaged and not rotating is how ford gets the mpg.
When in 2 we my axels are stationary. Same on my '12 and my dads '10.


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Huck said:

Your incorrect. the hubs unlock at the wheels and the transfer case disengages. That's the whole point of the IWE system.
With everything disengaged and not rotating is how ford gets the mpg.
When in 2 we my axels are stationary. Same on my '12 and my dads '10.


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Learn something new everyday. Looks as though my IWE system is ******. Jacked up the front end and both axles were moving when I spun the tires by hand when the truck was on. Put the truck into 4hi, went forward, backwards, put the truck back into 2HI and the axles stopped moving so the IWE system disengaged finally. Who knows how long Ive been running around like this. Drove around a bit and had the wife drive will I walked by the truck and watched the axles and they were slowly moving so it seems the system is slightly engaged still. My guess the metallic rattle is the IWE/Hub falling apart inside. If you watch the video you can see a ring of grease/oil right where the axle goes into the hub/IWE too.

Could the front diff get messed up from running around with the IWE engaged for who knows how long without the truck actually being in 2HI? Thats what Im worried about now.

Looking at other posts on FB it could be a faulty check valve.

Most likely my issue too. This was posted way back in May.

hmm... interesting. Might be worth picking up a spare

smurfslayer said:

hmm... interesting. Might be worth picking up a spare

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If that does turn out to be the problem Ill pick up a few since they are $9 and a couple guys have already needed to change theirs more than once. Seems Ford still hasnt learned.

I have to take mine in as I loose vacuum under WOT and the engine chokes and the hubs try to engage.

There should be no damage in 2 with the axels spinning. Just added wear and tear as the transfer case is still disengaged


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