I bet you can guess the answer to both those questions. They did say they would "help me out" because it was so expensive again. Also, the transfer case has a 2 year warranty, so that's something.
Here's hoping this fixes the issue.
I have not thought of fan engaging.
There is a slight change in the sound that corresponds to speed, just not typical pitch increase. It's a subtle increase of volume and the rhythmic sound gets faster. Also I can hear the fans running distinctly from this noise. That makes me think it's not fan.
I took it back to the dealer and just left if with them, asked them to just track down the noise and not throw parts at it. Will update if/when I find out anything.
It
It turns the axle, seems to be locked in at the hub. Ford Mechanic guys were vague about this, but indicated that it was "probably normal" that the transfer case was "probably not engaged". And it doesn't feel like 4wd when driving, so they may be right about that.
I have a 2012 FWD Expedition EL with about 150k miles. I just bought it used. I noticed a roaring noise from the front left wheel area. It becomes noticeable about 15mph until road noise drowns it out at about 50mph. Sounds like wheel bearing, but had the whole wheel hub replaced and still does...
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