Gen 1 IWE replaced

[rschap1]

After putting it off for QUITE a while.
Finally replaced my driver's side IWE yesterday.
Anytime I think of disconnection a tie rod end and/or ball joint, I worry.
BUT,
went pretty well (for me).
Probably close to an hour start to finish.
If I would have left the ball joint in place with the taper stuck in the spindle, might have shaved another 10 -15 minutes off.
Loosened up it's nut and was just happy to see them separate.
Then had to work wrenching the nut off the threads.
Had to work hard to get a deep well 10mm socket on the hex on lower part of the ball joint.
Took enough torques that corners rounded in a 10mm box end.
Everything else seemed to go well.
AND
Seemed like it was working and actuating like it was supposed to when all together.

Had a little clicking, rattling while driving since I got the Raptor.
Went away with 4WD actuated.
So I knew it needed something.
Fixed all the lines up, still noise.
Unplugged the vacuum solenoid about a week ago.
All quite.
Had the part in my console for 6-8 months.
Finally fixed.

May even replace the HVAC actuator soon.
New one has been in the console awaiting install even longer.

All the help I have had here makes it jump in.
Appreciate it all.
THANKS to everyone that has offered help and advice.

 

[rschap1]

Well...
Wondering if better or worse now?
The old IWE was pretty silent and smooth when engaging regardless of speed.
I probably shifted in and out of 4wd 65-70mph.
The new one clunks and makes some pretty good noise when engaging.
Wondering if more grease was/is needed?
Will it "wear in"?
Anyone else had one do anything like that after replacing?
THANKS again !!

 

[FordTechOne]

Well...
Wondering if better or worse now?
The old IWE was pretty silent and smooth when engaging regardless of speed.
I probably shifted in and out of 4wd 65-70mph.
The new one clunks and makes some pretty good noise when engaging.
Wondering if more grease was/is needed?
Will it "wear in"?
Anyone else had one do anything like that after replacing?
THANKS again !!

Did you compress the diaphragm with a vacuum pump before installation and measure the axle protrusion through the hub to verify the splines fully engaged?

 

[stevenstommyboy1]

Did you compress the diaphragm with a vacuum pump before installation and measure the axle protrusion through the hub to verify the splines fully engaged?

This quote could go so many directions.

 

[rschap1]

None of the above...
Did not do anything besides spread grease on the "gear" and splines, bolted it on, and re-assembled.
I did start the truck, shifted 2 wheel to 4 wheel a couple ties, and it seemed to do what it needed to before putting wheel and tire back on.
If shifting going slow enough, 5-10 mph roll, seems good.
Much more speed/faster than that and pretty noisy clunking pretty loudly.

 

[FordTechOne]

None of the above...
Did not do anything besides spread grease on the "gear" and splines, bolted it on, and re-assembled.
I did start the truck, shifted 2 wheel to 4 wheel a couple ties, and it seemed to do what it needed to before putting wheel and tire back on.
If shifting going slow enough, 5-10 mph roll, seems good.
Much more speed/faster than that and pretty noisy clunking pretty loudly.

Well, there’s your problem. You’ll probably need to order a new one at this point since it’s already making noise.

 

[rschap1]

I didn't realize there was anything more to installation than bolting new one on.
Is there a procedure to follow? Stuff to look for?
Noise only happens as it engages, nothing while driving in 2wd or once engaged in 4wd.

THANKS for letting me know

 

[rschap1]

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.

 

[rschap1]

Looked closer at the old(er) passenger side IWE last night.
It seemed to work, but...
twisting the axle by hand there is a LOT more "slop" in this one than the new (driver's side).
If I can twist the new one about .020" - twisting axle .010" cw, then .010" ccw; the old one probably has close to 1/8" twist. Feels like 5-10 times the mount of room to twist. Ordered another one for that side. Fingers crossed that is the trouble.

 

[CleverGirl_]

Call me old fashioned but i can never bring myself to switch on the fly. Is there any reason you haven't gone the IWE delete route?