Noise @ 60-70km/hr

[ericnyce]

So I'm losing my mind. I bought a used Ford Expedition Eddie Bauer with 180km on it. I've driven it for 25 more and i really like it but this noise is driving me crazy!!

Took to a few shops and dealer and thrall pointed to hub assemblies. I changed four and still have the noise so I followed some reccomendations here and changed the front, rear and transfer case oil. Swapped tires around as well. No luck!

So I took to another shop and they put on hoist and called me in to listen to the transfer case. Was groaning loud during the speed I was hearing it. So I found a used one with 60,000km on it and swapped it today. Still have the noise!!!

I don't know what else to do...

HELP!!

 

[mindgame]

Change your IWE vacuum solenoid.. It is like $30. This solenoid allows vacuum to disengage the auto locking hubs. This thingy is located on the passenger side firewall near the battery..

 

[ericnyce]

I forgot about that. I verified both the solenoid and actuators work but ordered them and changed them and still no difference. I suspected maybe a vacuum leak but those lines all work flawless.

Last night I rotates tires and I have one tire that's worn a couple mm more but really doubt that's it.

I have the ujoints but mechanic says they are fine. Really at a loss for words. Bought to trade this in but my only choices are limited as I need 3 rows and a v8

 

[mindgame]

Try checking for vacuum leak by using a vacuum pump w/gauge.. Remove the bigger size tube from the IWE solenoid and stick the vacuum there. pump to pressure -25psi.

If you can lift the expy, try spinning the front tires.. They should both spinn freely and not make any noises..

Another option to temporarily deal with the noise, is to remove the 2 front half shafts..
Just remove the front spindle nuts (20ft/lbs), and 6 bolts on the differential side..

 

[CapitanRon]

So I'm losing my mind. I bought a used Ford Expedition Eddie Bauer with 180km on it. I've driven it for 25 more and i really like it but this noise is driving me crazy!!

Took to a few shops and dealer and thrall pointed to hub assemblies. I changed four and still have the noise so I followed some reccomendations here and changed the front, rear and transfer case oil. Swapped tires around as well. No luck!

So I took to another shop and they put on hoist and called me in to listen to the transfer case. Was groaning loud during the speed I was hearing it. So I found a used one with 60,000km on it and swapped it today. Still have the noise!!!

I don't know what else to do...

HELP!!

Hi,
New to this forum, peruse the Ford-Trucks site mostly. Several threads on that site relating to the noise issue you describe. I own a 2003 Expedition EB with 4WD and a 5.4L. I am also experiencing the same noise. I've opted to live with the noise rather than throw money at it. I know that there are a couple of TSB's referring to the noise. One I am searching for is TSB 17135 or the NHTSA Action # 10004051. I can read the synopsis which refers to Flex couplings in the exhaust system, but I haven't found the complete TSB to find what solutions are recommended. No parts diagrams I have been able to find on line have flex couplings in them, so can't even find a part #. Unfortunately it seems several things cause the same or similar noises as you have discovered.
Hope you can find a solution to your noise.

 

[ericnyce]

You can imagine the money I've thrown at this...my good deal on the truck is slowly disappearing haha. I tried the vacuum leak test and found nothing. Because I couldn't test while driving I opted to change the actuators and solenoid.

I enjoy working on vehicles so I'm not completely bummed about this but I'm regretting my past decade of Hondas haha

Oh and I put on a Magnaflow cat back exhaust after the hubs because I "gave up" chasing the noise... But it's even more noticeable when it's overpowering my exhaust...

I'll check the TSB you mentioned and if you have any luck let me know

 

[FordandPolaris]

Look into the sway bar endlinks! Especially if the noise is occuring while hitting bumps etc. during driving.

 

[CapitanRon]

You can imagine the money I've thrown at this...my good deal on the truck is slowly disappearing haha. I tried the vacuum leak test and found nothing. Because I couldn't test while driving I opted to change the actuators and solenoid.

I enjoy working on vehicles so I'm not completely bummed about this but I'm regretting my past decade of Hondas haha

Oh and I put on a Magnaflow cat back exhaust after the hubs because I "gave up" chasing the noise... But it's even more noticeable when it's overpowering my exhaust...

I'll check the TSB you mentioned and if you have any luck let me know

Yes, I can do the math on what you have put out to date. These vehicles seem to be a real gold mine for mechanics and parts suppliers. A coolant leak at the infamous aluminum crossover pipe on the plastic intake manifold mating just cost me $1400 plus. Plastic just deteriorated. How Ford has managed to avoid class action suits on these poorly designed units is a mystery to me. They shelled out some big bucks back in 2002 for some late 90's Crown Vics with the 4.6L and plastic intake manifolds, but have continued to put them on just about everything they make.

I'm guessing not many lawyers drive Fords.

Still looking for that TSB, but no luck to date. Anyone with a copy they could scan and post or email would be greatly appreciated.

 

[ericnyce]

I swapped the rear sway bar links as well haha.

I hope I don't have much more issues...but in all honesty I've changed all these parts prematurely. I blame the mechanics...false diagnosis. I would pay $1400 to fix this noise though!! But at the same time I feel for you on the major repairs...

The tsb was for this:
Moaning noise from the exhaust system, or vibration in the rear passenger floor pan, when driving 45-55 mph and 1200-1400 rpm all without flex coupling in the exhaust.

 

[CapitanRon]

I swapped the rear sway bar links as well haha.

I hope I don't have much more issues...but in all honesty I've changed all these parts prematurely. I blame the mechanics...false diagnosis. I would pay $1400 to fix this noise though!! But at the same time I feel for you on the major repairs...

The tsb was for this:
Moaning noise from the exhaust system, or vibration in the rear passenger floor pan, when driving 45-55 mph and 1200-1400 rpm all without flex coupling in the exhaust.

Yes that is the synopsis of the TSB. The complete TSB lists the symptoms and the procedures and parts Ford thinks will remedy the symptoms. That is what I am searching for. Sometimes you can get a TSB from the dealership, especially if they think you will pop for the fix. I'm not on great terms with my local dealership due to some issues with another Fix Or Repair Daily product.

 

[ericnyce]

I was driving today on the highway and pulled over. I pulled the hose connected to the Actuator and I had little to no vacuum from it?!?!? I got home and turned it off, came back later to start the vehicle and pulled the same hose and had vacuum!?!? Any idea what's going on??

 

[mindgame]

I was driving today on the highway and pulled over. I pulled the hose connected to the Actuator and I had little to no vacuum from it?!?!? I got home and turned it off, came back later to start the vehicle and pulled the same hose and had vacuum!?!? Any idea what's going on??

Check valve to the IWE Solenoid?

I personally would have yanked the half shafts until I can locate the leak..
Yanking the half shafts will take me 10 minutes per shaft.. Then again... I had alot of practice

 

[ericnyce]

I have a brand new solenoid in there. Maybe I'll pull off the half shafts. It's just a few bolts hey? Doesn't leak fluid when they are removed?

 

[mindgame]

I have a brand new solenoid in there. Maybe I'll pull off the half shafts. It's just a few bolts hey? Doesn't leak fluid when they are removed?

The check valve is located elsewhere on the vacuum line.. As for where it is.. I have no clue...

No leaks.. They are solid and heavy..

1. Remove the front spindle cap, and remove the small bolt connecting the half shaft to the wheel hub.
2. Remove the 6-12sided bolts (12mm?) bolts from HS connecting to the front diff .
You will need to giude the HS into a location to where you can safely pull out the spline from the wheel hub. If you cant, and need more room. Remove the top bolt connecting the upper control arm to the wheel knuckle assembly.
3. Cover the back side of locking hubs to prevent large dirt and things from getting into the hubs... I used aluminum tape to cover my locking hubs instead of duct tape, when I had to remove my half shafts for CV boot repairs..

Hope this helps..

 

[mindgame]

This is for an 04 Expedition... You will need to research to get the torque specs appropriate for your year/model.. But you can use this as a guide..

 

[ericnyce]

Been super busy...i haven't pulled the half shafts...i however did swap out the front u-joints today...still have the noise!! I invested in a vacuum gauge as well and tested every possible component of the IWE system...all hold vacuum with no issues...even the old actuator and solenoid work fine...love the vehicle but guess who's visiting the local dealers! haha

 

[mindgame]

hmm... Looks lke we are looking in the wrong places.. Know of anyone with a Steelman Wireless Chassis Ear? This will help to identify exactly where the noise is coming from..

 

[Notmyidi]

Chassis ear, far cheaper than the money you've spent, but at this rate your vehicle is nearly restored

sent from my mind via of telepathy

 

[ericnyce]

Haha your right! Only thing left are the diffs themselves and the half shafts. I won't lie, at first I enjoyed changing parts. Maybe I'll do one or two more and stay away from a new vehicle and the headaches they bring (monthly payments) haha.

I'll ask around about the chasis ear. Small towns all around me so I doubt I'll have any luck.

 

[Notmyidi]

Harbor freight sells a cheap set, wireless ones are nice

Watch it be a pinion bearing

sent from my mind via of telepathy