Subtle Vibration and Random Metallic Noise

[BinaryExpert]

Thanks all for sharing helpful information and helping others.

I bought a new 2019 Expy Max Platinum 3 months ago and drove about 6100 miles so far. Started from about 3 weeks ago, it does not drive as solid/quiet/smooth as before. I feel a very subtle vibration continuously coming from the bottom of the car (feel more clearly from acceleration pedal and a bit from steering wheel as well). It feels like a subtle metal grinding (and possibly dragging although I can't tell) and I feel it better when the car is coasting straight at low speed in the morning. Although I don't hear anymore, I (and my wife) also heard several times a pretty loud metallic noise/rattle for a very short period time (1~2 second). I suspect this is how it started. They don't seem to be related to steering/acceleration/braking as they are pronounced when the car is coasting straight. The speed does not seem to be related either. I still hear a small (not loud anymore) random metallic noise from the bottom from time to time mostly in the morning.

From symptoms, I suspect u-joint, brake disc/rotor, shaft connections or lack of lubrication, but it could be a completely different thing as the car mechanics are complex. Any advice or suggestions?

 

[AAOO]

2WD or 4WD?

 

[BinaryExpert]

I always drive in 2H. I tried 4A but no difference at all. Thanks anyway.

 

[aggiegrad05]

https://static.nhtsa.gov/odi/tsbs/2018/MC-10149748-9999.pdf

Check out that link. That is why he asked if you have a 2wd or a 4wd (I think). I had the same issue with mine.

 

[BinaryExpert]

Oh.. Thank you so so so much! I just made a service appointment, and will post any result here.

 

[AAOO]

https://static.nhtsa.gov/odi/tsbs/2018/MC-10149748-9999.pdf

Check out that link. That is why he asked if you have a 2wd or a 4wdc (I think). I had the same issue with mine.

Exactly why I asked. Thanks for posting aggie!

 

[BinaryExpert]

I just got back from my test drive in 4A, and am very disappointed. It still happened in 4A. Is it possible this exact problem could happen in 4A (if engaging/disenganging is not perfect, maybe)?
I also found this interesting YouTube

 

[BinaryExpert]

I just got back from my test drive in 4A, and am very disappointed. It still happened in 4A. Is it possible this exact problem could happen in 4A (if engaging/disenganging is not perfect, maybe)?
I also found this interesting YouTube

 

[aggiegrad05]

I just got back from my test drive in 4A, and am very disappointed. It still happened in 4A. Is it possible this exact problem could happen in 4A (if engaging/disenganging is not perfect, maybe)?
I also found this interesting YouTube

Honestly, I don’t remember if mine happened in 4 as well or just 2. I THINK it was both because it’s an engagement issue, but possibly not because the issue stems from the fact the system can’t hold in 2 and slips into 4; so if you’re choosing 4 I would think the issue would not present.

But I just don’t remember, I’m sorry.

 

[BinaryExpert]

Thanks Aggie. You helped me a lot already. BTW, I tried to record the sound this morning to show to a technician tomorrow, and the grinding noise/vibration seemed to get worse since my 2H/4A test yesterday. It happens as much or more in 4A as in 2H. The sound is recorded but it is not crystal clear when I replay.
On a slightly different note, I made an appointment at different dealership this time as I don't like the dealership where I bought the car. Is there any danger in this change with respect to warranty coverage? Any advice would appreciated. Thanks!

 

[S Mathieson]

I am having a similar issue with my 2018 Expy Plat Max, however my new 2019 F150 LTD is even worse!!
Unit only has 3500 kms on it and the dealer has replaced, Axels, Differencial, Drive Shaft etc etc etc !
The "Icing n the Cake" is unit sustained $4000.00 in hail damage while it was at the dealership!! The Dealer and Ford Canada refuse to replace the vehicle? I have owned this unit since June of this year and have only been able to drive it for a matter of weeks do to the mechanical issues. I was considering on changing my fleet over to Ford however thinking differantley now!
Might be time to get my Attorney involved?

 

[BinaryExpert]

Although I failed to reproduce the problem to technician, I'd like to share useful information I learned from my service visit. My noise and vibration are usually pronounced within 5 minutes of driving when they happen, which indicates that it is related to IWE operation. Anyway, below is official information.

SSM 48088 - 2019 F-150/Expedition/Navigator - 4WD - Revised IWE Operation Strategy After Initial Start Up
2019 F-150/Expedition/Navigator vehicles equipped with four-wheel drive (4WD) have a revised transfer case control module (TCCM) strategy that will affect IWE operation after initial start up. The TCCM will not energize the solenoid to supply vacuum to the IWEs after the initial key cycle and a driven gear is selected. The IWEs will remain engaged for 0.8 km (0.5 mi) when the temperature is above 0 C (32 F) and 3 km (2 mi) when below 0 C (32 F). The strategy changes were implemented to improve vacuum supply management and axle warm up in cold temperatures. The engine must run for a minimum of 5 minutes to build sufficient vacuum before performing any vacuum related testing. Refer to the workshop manual section 307-08A.

If you have heard any metallic noise and vibration (small or big) from near front wheel within first few minutes of driving in the morning, please leave a comment here.

 

[Todd C]

I made an appointment for my 2019 Exp Platinum for this week. There are subtle bumps on the street leading to my house, it's embarrassing and saddening to rattle down the road. Sometimes the rattle sounds like a pebble in an old hubcap. This problem started around 6K, I'll post an update when the problem is addressed.

 

[NukeLife]

I wonder if this is what I have going on. I have an issue (not always there) that feels like slight shuddering in the drivetrain. It is more noticeable when under very light acceleration at low speeds. You can feel the vehicle jolt like the transmission is slipping. Going slowly up a steep grade will make it more pronounced.

I was towing a 4000 lb trailer last week and it happened again under light acceleration, but much scarier feeling with that heavy load on it.

 

[Deadman]

Some have had issues with their rear differential.....check it out.