Torsen front axle problems ! anyone else ???

another ******* clunker

I have the same driver's side front end 'clunk' in 4wd. I am so pissed off that I feel like burning the truck... before I do that, it sounds as though there are a few people who have had the same problem but have managed to have it resolved. Any guidance on what got it fixed? Mine is a 2012 Scab with very few off-road miles. In 2wd it is fine, in 4wd in soft sand, it clunks like crazy and sounds like it is digesting itself. No-one seems to be able to diagnose the problem, let alone repair it.

- What has been the solution for other people who have had the same experience?

- I have replaced the driver's side hub. Should I go ahead and replace axle etc also?

- Does anybody want to buy a lightly used 2wd 2012 Raptor?! for you, special price....

thanks for any help or advice. I am not really in the market for customised stuff as it is hard to get in and to Dubai, but I am happy to throw money at the problem if there is a sure way to get rid of the issue.

Nooe new test axles are still not ready... Having issues

Dealership fixed it for me. Not all sure what they did they replaced a bunch of stuff though!

I haven't followed the 14s, but I assume the torsen font end still exists?

Yukon Joe
www.RUNRAPTORRUN.com

Torsens are all but useless with Ford crappy automatic hub design!

(crawls back into his cave)

-Greg (aka squatting dog)

clunking in action..

I absolutely love my Raptor but I have no faith in the 4WD system. My truck is a street queen and rarely sees dirt. It seems like every time engage the 4wd, something breaks and ultimately leaves me stranded/stuck. My truck is completely stock, no mods, and I have gone through my share of IWE's, one broken CV, and the most recent repair required the complete replacement of my front differential (including the housing) due to a "Catastrophic Internal Failure." After getting the truck back from the dealership, I went out to test the 4wd and ended up with a clunking noise again. I took some video of the truck clunking for the dealer. Truck is back in the shop and dealer is saying the transfer case is the culprit and they are going to replace it. In the video, you can see I'm not romping on it, rather I am just easing into the throttle (4wd lo, off-road mode enabled) to get it to creep up a slight hill and it seems like something lets go the truck makes a pretty horrific clunk/bang. I never had any issues with my 2010 Raptor.. Any thoughts?


Clunked Raptor - YouTube

FYI truck is a 2012 Supercrew.

Iwe is broken. Mine had the same noise. The splined part is probably worn down. I cant load the video im too far in the middle of nowhere to load it will check tonite . Ive broken 4 hubs, like 5 pairs of iwes, 5 pair of oem cv axles. All because the iwe wasnt engaging properly.
Now i have a aftermarket mini vacuum pump which doesnt connect to solenoid throttle for vacuum instead this mini pump is way more powerfull and keeps vacuum when i need it and keeps it tight. Separate in cab switch.
Now im running aftermarket hubs, iwes, rcv test axles and im pounding it so far so good

Netix said:

Now im running aftermarket hubs, iwes, ....

Click to expand...

Who offers aftermarket hubs and IWEs? I would love to see a write up on your vacuum pump.

Interesting to read of other people with the same problem. I have been through a whole series of repairs- now on another new Hub and the clunking noise is still there. The noise is very similar to the one on the youtube link above. Was the cause for this ever accurately diagnosed? Was it the transfer case? If so…. any idea why?!

Are most of the owners that are having problems with the iwe carefully engaging the four wheel drive . Not under load and slower speeds.