2020 crazy noise while accelerating

[johnlawler]

Hey! This is my first post, and my first expedition! Bought a 2020 XLT 4x4 with 53k miles. A couple of days after driving off the lot I heard a crazy noise underneath the expedition. Sounds kind of like something is clunking around underneath while accelerating. You can hear it in the attached video (if I linked it right). I’ve heard it in 2-6th and 8th gears. I once heard it slightly going around a turn under acceleration. It stops when I take my foot off the gas. Or when it stops by itself it sounds kind of like a valve or door shuts underneath the expedition. Carfax said the transmission was rebuilt at 49k miles. The dealership has had it now for 3 weeks. They originally thought it was the starter (which didn’t make any sense to me!) I picked it up and 10 minutes down the road heard the sound again. They’re now saying they can’t get it to reproduce the sound, but I can do it every time I drive it. Need help! Any thoughts on what it might be?

Here’s a link to the video:

Expedition noise while accelerating

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[DieselMonk]

Hmm… sounds weird. Only does this while driving? Not when you tap the throttle in park or neutral standing still? Does it change sound if you go faster or slower? Didn’t hear a clunk, rather you driving over like a bridge expansion joint and a weird screeching sound.
Try auto 4wd or 4wd and see what that gives

 

[99WhiteC5Coupe]

Hey! This is my first post, and my first expedition! Bought a 2020 XLT 4x4 with 53k miles. A couple of days after driving off the lot I heard a crazy noise underneath the expedition. Sounds kind of like something is clunking around underneath while accelerating. You can hear it in the attached video (if I linked it right). I’ve heard it in 2-6th and 8th gears. I once heard it slightly going around a turn under acceleration. It stops when I take my foot off the gas. Or when it stops by itself it sounds kind of like a valve or door shuts underneath the expedition. Carfax said the transmission was rebuilt at 49k miles. The dealership has had it now for 3 weeks. They originally thought it was the starter (which didn’t make any sense to me!) I picked it up and 10 minutes down the road heard the sound again. They’re now saying they can’t get it to reproduce the sound, but I can do it every time I drive it. Need help! Any thoughts on what it might be?

Here’s a link to the video:

Expedition noise while accelerating

Enjoy the videos and music you love, upload original content, and share it all with friends, family, and the world on YouTube.

m.youtube.com

Since the noise occurs every time you drive the vehicle, did you ask the service advisor or technician to ride with you while you drive it?

 

[Ugh_J]

Know anyone with a dyno? If you can reproduce it there where you can inspect it from outside, that'd likely be the quickest way to isolate it. Failing that, have someone else drive while you move around and see if you can determine where the noise is generally coming from (front/engine, rear, a door, the moonroof, etc.).

 

[Mr Big]

Because it only does it when accelerating, a bad catalytic converter or muffler could make noise. Or since you are 4wd, it could be something there. If you are handy, jack it up and inspect the exhaust system?

 

[johnlawler]

Thanks guys! Unfortunately, it’s still at the dealer. I drove it with the tech and he had no idea what it could be. They said the Ford engineer said to start with replacing the separator plate to make sure everything’s aligned between engine and tranny. The more research I’ve done the more I’m inclined to think failing IWE system since it’s 4wd. Maybe check valve or actuators?

Once they replace separator plate, I’m gonna take it for a spin with the tech and service manager to see if I can replicate the noise. If so, I may even bring a replacement check valve and replace it in the parking lot to see.

 

[brett1210]

I have the exact same issue on my 2018 Limited with 72,000 miles. I've had it to the dealer twice and they have been having a hard time getting it to happen while they drive it. So far they've replaced the cam phasers and rebuilt the transmission (CDF hub issue). It's going back on Aug 14th and I'm going to drive it while the chassis ears are on. Please let me know if you figure out what your issue is before then.

I've suspected the driver's side turbo all along. If that noise is occurring and I add some throttle, the rattle gets louder until something finally thunks, which I can physically feel in the floorboard. Then the noise is gone. It seems to only happen after the truck is warmed up, then parked for 5 to 10 minutes, and I drive away with light accelleration. Really looking forward to solving this mysterious issue!!!!

 

[johnlawler]

I have the exact same issue on my 2018 Limited with 72,000 miles. I've had it to the dealer twice and they have been having a hard time getting it to happen while they drive it. So far they've replaced the cam phasers and rebuilt the transmission (CDF hub issue). It's going back on Aug 14th and I'm going to drive it while the chassis ears are on. Please let me know if you figure out what your issue is before then.

I've suspected the driver's side turbo all along. If that noise is occurring and I add some throttle, the rattle gets louder until something finally thunks, which I can physically feel in the floorboard. Then the noise is gone. It seems to only happen after the truck is warmed up, then parked for 5 to 10 minutes, and I drive away with light accelleration. Really looking forward to solving this mysterious issue!!!!

They replaced the separator plate and it’s still making the grinding noise. I took it to another Ford dealer in town and they said, “We heard that same noise last week!” Hopefully they’ll get to it soon and I can give you an answer before you take yours in.

 

[Ugh_J]

Integrated front wheel hub 4wd grinding $20 upgrade. “Save your front wheel hubs easily”

So I took my car to the dealer and asked him if this can be changed in my 22 timberline. Unfortunately they say the vacuum is controlled through the TCM and no such valve exists in this model. Wonder if that is any true. If so how can the problem be fixed because I still get the noise...

www.expeditionforum.com

Possible? There's a video in that post with the noise so you can compare to what you're hearing.

 

[johnlawler]

Just a quick update. Second Ford dealer knows what they’re doing! It was the check valve for the IWE. Went bad and they capped the system and reprogrammed the module.

Thanks for your advice guys! I’ve learned a ton in the first month of owning my “new to me” expedition.

 

[ROBERT BONNER]

Just a quick update. Second Ford dealer knows what they’re doing! It was the check valve for the IWE. Went bad and they capped the system and reprogrammed the module.

Thanks for your advice guys! I’ve learned a ton in the first month of owning my “new to me” expedition.

Unfortunately, "capped the system" sounds like they followed the universal IWE TSB (written by a moron) which means they disabled the system and your hubs are now engaged all of the time contributing to premature front drivetrain wear, excessive high speed NVH and reduced fuel economy. With a vacuum pump/gauge and a little common sense, the systems are pretty easy/inexpensive to troubleshoot and repair to put back to design function. I have fixed two of my hunting buddies F 150's that the dealers disabled (following the TSB). Root cause for one was a valve and the other was actually a completely failed wheel bearing.

 

[johnlawler]

Unfortunately, "capped the system" sounds like they followed the universal IWE TSB (written by a moron) which means they disabled the system and your hubs are now engaged all of the time contributing to premature front drivetrain wear, excessive high speed NVH and reduced fuel economy. With a vacuum pump/gauge and a little common sense, the systems are pretty easy/inexpensive to troubleshoot and repair to put back to design function. I have fixed two of my hunting buddies F 150's that the dealers disabled (following the TSB). Root cause for one was a valve and the other was actually a completely failed wheel bearing.

Robert, thanks for the advice. I assumed that since it can run 4A all the time it wouldn’t do much harm. But it makes sense that engaged hubs would lead to premature front end failure.

Would a repair just look like replacing the old vacuum hose and check valve? Thanks for the help.

 

[ROBERT BONNER]

The attached simple schematic shows the IWE basics. Different vehicles have the components located in different locations. Function is simple. When vacuum is applied to the wheel clutches, they disengage, allowing the wheels (hubs) to rotate free from the axles. When vacuum is denied, the clutches spring engage the drive splines on both the axles with the hubs, connecting them. Failures occur from vacuum leaks in the system and or failure(s) of the actuator solenoid or check valve(s). You can easily check the system and the components with a hand vacuum pump/brake bleeder. Start at the engine vacuum line applying vacuum and checking for bleed down, there should be NO bleed down, if there is, work your way down stream until you isolate the leaking component. If there are no leaks; but, there is still grinding, then the solenoid and or check valves are suspect which can be trouble shot with a vacuum gauge. Though, I've never seen it, theoretically, plugged vent lines (shown in blue on the schematic) could cause problems as well.

If one of the wheel clutches is leaking, replace both. If grinding persists when all components of the IWE system are working properly (as I found once), a failed wheel bearing can cause enough axial movement of the wheel hub to lead to grinding.

Good luck! As modern vehicles go, I find the IWE system on these trucks to be one of the simplest systems to troubleshoot and maintain.

 

[The Yeti]

I have the exact same issue on my 2018 Limited with 72,000 miles. I've had it to the dealer twice and they have been having a hard time getting it to happen while they drive it. So far they've replaced the cam phasers and rebuilt the transmission (CDF hub issue). It's going back on Aug 14th and I'm going to drive it while the chassis ears are on. Please let me know if you figure out what your issue is before then.

I've suspected the driver's side turbo all along. If that noise is occurring and I add some throttle, the rattle gets louder until something finally thunks, which I can physically feel in the floorboard. Then the noise is gone. It seems to only happen after the truck is warmed up, then parked for 5 to 10 minutes, and I drive away with light accelleration. Really looking forward to solving this mysterious issue!!!!

Brett - did you ever find out what was going on with yours? I have the same audible rattle which is eventually followed by the "thunk", unless I come off the accelerator and let it coast. Sometimes that will avoid it. The dealer says that found a loose exhaust shield bracket, but I'm still skeptical. I don't see how the shield could cause a "think". It's only happening occasionally, so it's hard for the dealer to replicate... I've already replaced the transmission once (@71,000miles) and I'm suspicious it is related. I only have 3000 miles left on the warranty of my new trans... Looking forward to any insights.

 

[brett1210]

Yessir, it was the IWE system. They capped the system per the TSB and I haven’t heard the sound ever since.