Ongoing IWE issues. Just deal with it forever?

I have a 2019 Raptor - I'm bringing it for the 4th time to have IWE issues addressed this morning. The truck has has about 6500 miles on it and I have had it for about 7 months. Do you all run into the IWE issue that frequently? In some of the other threads folks mention keeping the replacement solenoid in their glovebox etc - honestly, having to do that annoys the hell out of me for a 70k truck. I'm seriously considering just selling the truck and getting something else... which sucks because I love the truck otherwise and there really isn't anything else that comes close; but the principle of the thing, having to fix a part on the truck every couple months is ridiculous. I could maybe eat it if it happened every other year or so but every couple months is rough. How often do you guys run into it?

2018 with 29k miles. Never had an issue.

Is it the same dealer doing the repairs? If so, maybe try another.

Derail said:

2018 with 29k miles. Never had an issue.

Is it the same dealer doing the repairs? If so, maybe try another.

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Yeah, though they actually have a couple of dealerships in the area and had their head of service come down to drive the truck w/ me to see (hear?) the issue. He mentioned they might need to get Ford involved. I'm happy to hear that you haven't had any problems - makes me think there is hope that this can be sorted!

Which dealer? I have been lucky I guess, no IWE issue but I do need my cam phasers replaced...

The IWE's are pretty delicate. Sad for this caliber of truck but true. Are you stressing the 4wd system much or is this just happening at random?

Pacific Wheel said:

The IWE's are pretty delicate. Sad for this caliber of truck but true. Are you stressing the 4wd system much or is this just happening at random?

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The system is not “delicate”. The issue occurring in this video is the result of partial engagement due to a vacuum leak and has nothing to do with the torque capacity of the IWEs themselves. The fact that the dealer cannot repair a simple vacuum actuated system is pathetic.

Ford released TSB 20-2028 (previously 20-2013) to assist dealers with diagnosing the exact issue you’re experiencing - an intermittent grinding noise from the front wheels while driving. It specifies model years 2013-2018, but the system on 2019 models is the same aside from a revised strategy in the calibration. The dealer cannot claim the TSB on the RO for warranty, but the diagnostics still apply.

The workshop manual also contains a pinpoint test for this exact issue. It’s pinpoint test F in section 308-07A. It’s very comprehensive and even includes photos of the procedures.

I would recommend contacting Ford corporate and advise them that your dealer has attempted to repair the concern 4 times without resolution. The customer relationship rep can reach out to other dealers in your area and find one that is willing to help. They typically know which dealers have high customer satisfaction and which to avoid. Often they can even schedule the appointment for you.

Let us know how it goes.

Excellent response to the OP's reoccurring IWE issue. I can relate to your frustration, especially after shelling out $65K plus for a Raptor.

FordTechOne said:

The system is not “delicate”.

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My experience has been different. Maybe I'm just unlucky. Two years in a row at Bucks Lake I had to pull the boat out. Its a very steep but paved ramp. Both years I ended up having to have them replaced. Dealer said they were cracked? The last few times we were there we used a friends 4Runner in 4 low without issue.

Pacific Wheel said:

My experience has been different. Maybe I'm just unlucky. Two years in a row at Bucks Lake I had to pull the boat out. Its a very steep but paved ramp. Both years I ended up having to have them replaced. Dealer said they were cracked? The last few times we were there we used a friends 4Runner in 4 low without issue.

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Sorry to hear you had trouble. An IWE is similar to a shift sleeve used in a transfer case or manual transmission; it’s a relatively simple design that consists of a splined collar that engages on to the hub splines. There is a spring inside the unit that engages the IWE to the hub when no vacuum is present.

What symptom did you experience when you had the issue on your truck?

Even folks that spend $300K on vehicles have issues - not sure any manufacturing process is perfect with any consumer product. what absolutely sucks is the dealer not being able to fix it. And to that end, some onus is on Ford to ensure dealers are capable. It's not just Ford, but this whole manufacture / dealer relationship pretty much sucks 80% of the time. It shouldn't be on the consumer to find a "good dealer" vs a "bad dealer".