TSB-20-2028

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TECHNICAL SERVICE BULLETIN
4WD - Intermittent Grinding Noise While Driving
20-2028
11 February 2020
This bulletin supersedes 20-2013. Reason for update: Incorrect Procedure
Model:
Ford
2013-2018 Expedition
2013-2018 F-150
Lincoln
2013-2018 Navigator
Summary
This article supersedes TSB 20-2013 to update the description of Labor Operation D.
Issue: Some 2013-2018 F-150/Expedition/Navigator vehicles equipped with four-wheel drive (4WD) may exhibit an
intermittent grinding noise while driving in two-wheel drive (2WD) mode most commonly on acceleration. This may
be due to a loss of vacuum to the integrated wheel end (IWE) actuators and/or wear of the IWE components. To
correct the condition, follow the Service Procedure steps to reprogram the transfer case control module (TCCM) and
replace any worn vacuum and/or IWE components.
Action: Follow the Service Procedure steps to correct the condition on vehicles that meet the following criteria:
• 2013-2018 F-150/Expedition/Navigator
• Equipped with 4WD
• Customer concern of intermittent grinding noise in 2WD mode
NOTE: Part quantity refers to the number of that service part number required, which may be different than
the number of individual pieces. Service part numbers contain 1 piece unless otherwise stated.
Parts
Part
Number
1104
-
Description
Quantity
Front Hub Bearing - Refer To The Parts Catalog For The VIN
Specific Application
1 Per
Affected
Side
W714743- Package Contains 4 Pieces,
Caliper Anchor Plate Bolt (2013-2014 F-150, 2013-2017
S439
2 Pieces Required Per
Expedition/Navigator)
Affected Side
1
W720613- Package Contains 4 Pieces,
Caliper Anchor Plate Bolt (2015-2018 F-150, 2018
S439
2 Pieces Required Per
Expedition/Navigator)
Affected Side
1
N802827S100
Package Contains 4 Pieces,
Front Half Shaft Nut (2013-2016 F-150 Built On Or Before 21 Piece Required Per
Aug-2016)
Affected Side
1
N802827S100A
Package Contains 4 Pieces, Front Half Shaft Nut (2016-2018 F-150 Built On Or After 31 Piece Required Per
Aug-2016, 2015-2018 Expedition/Navigator Built On Or After
Affected Side
14-Apr-2015)
1
N802827S441
Package Contains 4 Pieces,
Front Half Shaft Nut (2013-2015 Expedition/Navigator Built
1 Piece Required Per
On Or Before 14-Apr-2015)
Affected Side
1
W520215- Package Contains 4 Pieces, Tie Rod End Nut/Upper Ball Joint Nut (2013-2014 F-150,
S441
1 Piece Required Per
2013-2017 Expedition/Navigator)
1
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Affected Side
W520215- Package Contains 4 Pieces,
Tie Rod End Nut (2015-2018 F-150, 2018
S440
1 Piece Required Per
Expedition/Navigator)
Affected Side
1
W520214S440
-
1
7L1Z3C247-A
-
HL1Z3C247-A
-
Upper Ball Joint Nut (2015-2018 F-150, 2018
Expedition/Navigator)
IWE Actuator (2013-2015 F-150 Built On Or Before 11-Oct2015, 2013-2015 Expedition/Navigator)
1 Per
Affected
Side
IWE Actuator (2015-2018 F-150 Built On Or After 12-Oct2015, 2016-2018 Expedition/Navigator)
1 Per
Affected
Side
W706890- Package Contains 4 Pieces,
S439
4 Pieces Per Side As
Front Hub Bearing Bolts
Required
HL1Z3C247-B
-
BL3Z3A788-A
-
FL3Z3A788-B
-
AL3Z3A788-A
-
BL3Z7A785-A
-
BL3Z7A785-B
-
FL3Z7A785-A
-
HL3Z7A785-A
-
AL1Z7A785-C
-
FL1Z7A785-A
-
JL3Z7A785-A
-
HL3Z3C125-A
-
FL3Z3C125-A
-
XG-1-E1
-
1 Per
Affected
Side
1 Per
Affected
Side
IWE Clutch Ring Kit
1
Check Valve (2013-2014 F-150)
1
Check Valve (2015-2018 F-150, 2018 Expedition/Navigator)
1
Check Valve (2013-2017 Expedition/Navigator)
1
Vacuum Lines (2013-2014 F-150 Excluding Raptor)
1
Vacuum Lines (2013-2014 Raptor)
1
Vacuum Lines (2015-2018 F-150 Excluding Raptor)
1
Vacuum Lines (2017-2018 Raptor)
1
Vacuum Lines (2013-2014 Expedition/Navigator)
1
Vacuum Lines (2015-2017 Expedition/Navigator)
1
Vacuum Lines (2018 Expedition/Navigator)
1
Vacuum Hose To IWE (2017-2018 Raptor)
Vacuum Hose To IWE (2015-2018 F-150 Excluding Raptor,
2018 Expedition/Navigator)
Motorcraft® Premium Long-Life Grease
1
As
Needed
Warranty Status: Eligible under provisions of New Vehicle Limited Warranty (NVLW)/Service Part Warranty
(SPW)/Special Service Part (SSP)/Extended Service Plan (ESP) coverage. Limits/policies/prior approvals are not
altered by a TSB. NVLW/SPW/SSP/ESP coverage limits are determined by the identified causal part and verified
using the OASIS part coverage tool.
Labor Times
Description
2013-2018 F-150, Expedition/Navigator 4X4: Inspect, Replace Check Valve, Apply Vacuum To
Operation
Time
No.
202028A
0.8
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Both IWEs (Pass) Road Test (Pass) (Do Not Use With Any Other Labor Operations)
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Inspect, Replace Check Valve, Apply Vacuum To
Both IWEs (Fail) Apply Vacuum Directly To Each IWE (One Fail) Remove One IWE, Inspect
Wheel Bearing Splines (Pass) Replace One (1) IWEs (Can Be Claimed With Operations K, L
And M) (Do Not Use With Any Other Labor Operations Outside Of This Article)
202028B
1.1
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Inspect, Replace Check Valve, Apply Vacuum To
Both IWEs (Fail) Apply Vacuum Directly To Each IWE (Both Fail) Remove Both IWEs, Inspect
Wheel Bearing Splines (Both Pass) Replace Both (2) IWEs (Can Be Claimed With Operations K,
L And M) (Do Not Use With Any Other Labor Operations Outside Of This Article)
202028C
1.8
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Inspect, Replace Check Valve, Apply Vacuum To
Both IWEs (Fail) Apply Vacuum Directly To Each IWE (Both Fail) Remove IWEs, Inspect Wheel
Bearing Splines (One Fail) Replace One (1) Wheel Bearing And Both (2) IWE’s (Can Be
Claimed With Operations K, L And M) (Do Not Use With Any Other Labor Operations Outside Of
This Article)
202028D
1.9
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Inspect, Replace Check Valve, Apply Vacuum To
Both IWEs (Fail) Apply Vacuum Directly To Each IWE (Both Fail) Remove IWEs, Inspect Wheel
Bearing Splines (Both Fail) Replace Both (2) Wheel Bearings And Both (2) IWEs (Can Be
Claimed With Operations K, L And M) (Do Not Use With Any Other Labor Operations Outside Of
This Article)
202028E
2.1
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Inspect, Replace Check Valve, Apply Vacuum To
Both IWEs (Both Pass) Road test (Fail One Side) Remove IWE, Inspect Wheel Bearing Splines
(Pass) Replace One (1) IWE Clutch Ring (Can Be Claimed With Operations K, L And M) (Do Not
Use With Any Other Labor Operations Outside Of This Article)
202028F
1.6
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Inspect, Replace Check Valve, Apply Vacuum To
Both IWEs (Both Pass) Road test (Fail Both Sides) Remove Both IWEs, Inspect Wheel Bearing
Splines (Pass) Replace Both (2) IWE Clutch Rings (Can Be Claimed With Operations K, L And
M) (Do Not Use With Any Other Labor Operations Outside Of This Article)
202028G
2.3
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Inspect, Replace Check Valve, Apply Vacuum To
Both (2) IWEs (Both Pass) Road Test (fail One Side) Remove IWE, Inspect Wheel Bearing
Splines (Fail One Side) Replace One (1) Wheel Bearing And One (1) IWE Clutch Ring (Can Be
Claimed With Operations K, L And M) (Do Not Use With Any Other Labor Operations Outside Of
This Article)
202028H
1.8
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Inspect, Replace Check Valve, Apply Vacuum To
Both (2) IWEs (Both Pass) Apply Vacuum Directly To Each IWE, Road test (Fails Both Sides)
Remove Both IWEs, Inspect Wheel Bearing Splines (Fail Both Sides) Replace Both (2) Wheel
Bearing And Both (2) IWE Clutch Rings (Can Be Claimed With Operations K, LAnd M) (Do Not
Use With Any Other Labor Operations Outside Of This Article)
202028J
2.6
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Additional Time Use Scan Tool To Active Solenoid
And Measure Vacuum At Both IWEs (Can Be Claimed With Operations A-J)
202028K
0.3
Hrs.
2013-2018 F-150, Expedition/Navigator 4X4: Additional Time To Be Used When Vacuum
Harness Replacement Is Necessary (Can Be Claimed With Operations A-J)
202028L
0.5
Hrs.
2017-2018 F-150, 2018 Expedition/Navigator 4X4: Additional Time To Be Used When TCCM
Reprogramming Is Necessary (Can Be Claimed With Operations A-J)
202028M
0.2
Hrs.
Repair/Claim Coding
Causal Part:
3C247
Condition Code: D4
Service Procedure
1. Is the vehicle a 2017-2018 F-150 or 2018 Expedition/Navigator built on or before 17-Sept-2018?
(1). Yes - reprogram the TCCM using the latest version of the appropriate Ford scan tool. Proceed to Step 2.
• Note: The new TCCM calibration changes IWE operation at start up. When ambient temperature is above 0°C (32°F) the
IWEs stay engaged regardless of a 4WD mode selection for approximately 0.8 km (0.5 miles). IWE engagement only occurs
once per key cycle and is not reset when shifting between PARK and DRIVE. The TCCM uses this strategy to delay vacuum
use until vacuum-intensive engine startup has completed and sufficient vacuum is available to fully disengage IWEs.
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(2). No - proceed to Step 2.
2. Inspect the IWE vacuum hoses. Refer to Workshop Manual (WSM), Section 308-07A. Are there any disconnected
or damaged vacuum hoses? (Figure 1)
(1). Yes - reconnect or replace the vacuum hose as required. Refer to WSM, Section 308-07A.
(2). No - proceed to Step 3.
Figure 1
3. Replace the vacuum check valve located near the vacuum reservoir. Refer to WSM, Section 308-07A.
4. Disconnect the vacuum line to the IWEs at the vacuum solenoid.
5. Connect a hand vacuum pump to the IWE vacuum supply line and apply 508 mm-Hg (20 in-Hg) of vacuum. Does
the vacuum drop more than 12.5 mm-Hg (0.5 in-Hg) per minute? (Figure 2)
(1). Yes - proceed to Step 6.
(2). No - connect the IWE vacuum supply line to the solenoid and proceed to Step 10.
Figure 2
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6. Using a hand vacuum pump, apply 508 mm-Hg (20 in-Hg) of vacuum to each IWE, one at a time, and monitor the
vacuum gauge. Does the vacuum drop more than 12 mm-Hg (0.5 in-Hg) per minute? (Figure 3)
(1). Yes - proceed to Step 8.
(2). No - proceed to Step 7.
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7. Replace the vacuum lines between the solenoid and IWEs. Refer to the WSM, Section 308-07A. Proceed to Step
12.
8. Remove the IWE assembly from the affected wheel. Refer to WSM, Section 308-07A.
9. Inspect the wheel bearing splines for damage or excessive wear. Are the wheel bearing splines damaged or
showing signs of excessive wear?
(1). Yes - replace the IWE assembly and wheel bearing. Refer to WSM, Section 308-07A and 204-01B. Proceed
to Step 12.
(2). No - replace the IWE assembly. Refer to WSM, Section 308-07A. Proceed to Step 12.
10. Test the IWE vacuum supply lines.
(1). Disconnect the vacuum supply line at the left or right IWE and connect a vacuum gauge to the supply line as
shown in Figure 4.
(2). Start the engine and allow it to idle for 5 minutes to build vacuum.
(3). Connect the appropriate Ford scan tool and enter TCCM datalogger.
(4). Active command the vacuum solenoid.
• IDS Vehicles: Command IWE_OS # to No.
• FDRS Vehicles: Command IWE_OUT_ENGAGED = No (False).
(5). Repeat this test on the opposite IWE vacuum supply line.
Figure 4
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11. Is the vacuum at both left and right supply lines greater than 254 mm-Hg (10 in-Hg)?
(1). Yes - proceed to Step 12.
(2). No - replace the vacuum lines between the solenoid and IWEs. Refer to the WSM, Section 308-07A. Proceed
to Step 12.
12. Road test the vehicle for noise by performing heavy accelerations in 2WD. Engage the 4WD system to verify
proper engagement/disengagement quality. Is a grinding noise present in 2WD mode that is not present in 4WD
mode?
NOTE: When ambient temperature is above 0°C (32°F) the IWEs stay engaged regardless of a 4WD mode
selection for approximately 0.8 km (0.5 miles).
(1). Yes - proceed to Step 13.
(2). No - repair is complete.
13. Remove the IWE assembly from the affected wheel. Refer to WSM, Section 308-07A.
14. Inspect the wheel bearing splines. Are the wheel bearing splines damaged or showing signs of excessive wear?
(1). Yes - replace the IWE clutch ring and wheel bearing. Refer to WSM, Section 308-07A and 204-01B.
(2). No - replace the IWE clutch ring. Refer to WSM, Section 308-07A.
© 2020 Ford Motor Company
All rights reserved.
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NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and
equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information
that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition
described affects your car or truck. Contact a Ford or Lincoln dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy
and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article.
The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supersede
this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.
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