TSB 20-2278

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TECHNICAL SERVICE BULLETIN
Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding
Noise While Driving
20-2278
15 October 2020
This bulletin supersedes 20-2189. Reason for update: update the affected vehicle lines
Model:
Ford
2013-2018 F-150
Summary
This article supersedes TSB 20-2189 to update the affected vehicle lines.
Issue: Some 2013-2018 F-150 vehicles equipped with electronic shift on-the-fly (ESOF) 4-wheel drive
(4WD) may exhibit an intermittent grinding noise while driving in 2-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
• Equipped with electronic shift on-the-fly (ESOF) 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. "As Needed" indicates the part is required but the number may vary or is not a
whole number; parts can be billed out as non-whole numbers, including less than 1.
Parts
Part
Number
Description
Quantity
W720613S439
Package Contains 4
Pieces, 2 Pieces Required Caliper Anchor Plate Bolt (2015-2018 F-150)
Per Affected Side
1
W714743S439
Package Contains 4
Pieces, 2 Pieces Required Caliper Anchor Plate Bolt (2013-2014 F-150)
Per Affected Side
1
N802827S100A
Package Contains 4
Pieces, 1 Piece Required
Per Affected Side
Front Half Shaft Nut (2016-2018 F-150 Built
On Or After 3-Aug-2016)
1
N802827S100
Package Contains 4
Pieces, 1 Piece Required
Per Affected Side
Front Half Shaft Nut (2013-2016 F-150 Built
On Or Before 2-Aug-2016)
W520215S441
Tie Rod Nut (2013-2014 F-150 Built On Or
Before 23-Dec-2014)
1
1
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Package Contains 4
Pieces, 1 Piece Required
Per Affected Side
W520215S440
Package Contains 4
Pieces, 1 Piece Required
Per Affected Side
Tie Rod Nut (2014-2018 F-150 Built On Or
After 24-Dec-2014)
W520214S440
Package Contains 2
Pieces, 1 Piece Required
Per Affected Side
Upper Ball Joint Nut (2013-2018 F-150)
1
1
7L1Z3C247-A
Package Contains 1 Piece, IWE Actuator (2013-2015 F-150 Built On Or
1 Piece Required Per
Before 11-Oct-2015, 2013-2015
Affected Side
Expedition/Navigator)
1 Per
Affected
Side
HL1Z3C247-A
Package Contains 1 Piece,
IWE Actuator (2015-2018 F-150 Built On Or
1 Piece Required Per
After 12-Oct-2015)
Affected Side
1 Per
Affected
Side
Package Contains 4
Pieces, 4 Pieces Required Front Hub Bearing Bolts
Per Affected Side
1 Per
Affected
Side
Package Contains 1 Piece,
1 Piece Required Per
IWE Clutch Ring Kit
Affected Side
1 Per
Affected
Side
W706890S439
HL1Z3C247-B
3A788
1104
-
Check Valve - Refer To The Parts Catalog For
The VIN Specific Application
Package Contains 1 Piece,
Front Hub Bearing - Refer To The Parts
1 Piece Required Per
Catalog For The VIN Specific Application
Affected Side
BL3Z7A785-A
-
BL3Z7A785-B
-
FL3Z7A785-A
-
HL3Z7A785-A
-
HL3Z3C125-A
-
FL3Z3C125-A
-
Vacuum Hose To IWE (2015-2018 F-150
Except Raptor)
XG-1-E1
-
Motorcraft® Premium Long-Life Grease
1
1 Per
Affected
Side
Vacuum Lines (2013-2014 F-150 Except
Raptor)
1
1
Vacuum Lines (2013-2014 Raptor)
Vacuum Lines (2015-2018 F-150 Except
Raptor)
1
1
Vacuum Lines (2017-2018 Raptor)
1
Vacuum Hose To IWE (2017-2018 Raptor)
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 4X4: Inspect, Replace Check Valve, Apply Vacuum To Both IWEs
(Pass) Road Test (Pass) (Do Not Use With Any Other Labor Operations)
Operation
Time
No.
202278A
0.8
Hrs.
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2013-2018 F-150 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 L, M And N) (Do Not Use With Any Other Labor Operations Outside Of
This Article)
202278B
1.1
Hrs.
2013-2018 F-150 4X4: Replace Check Valve, Apply Vacuum To Both IWEs (Fail)
Apply Vacuum Directly To Each IWE (One Fail) Remove IWE, Inspect Wheel
Bearing Splines (One Fail) Replace One (1) Wheel Bearing And One (1) IWE (Can
Be Claimed With Operations L, M And N) (Do Not Use With Any Other Labor
Operations Outside Of This Article)
202278C
1.2
Hrs.
2013-2018 F-150 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 L, M And N) (Do Not Use With Any Other Labor Operations Outside Of
This Article)
202278D
1.8
Hrs.
2013-2018 F-150 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 L, M And N) (Do Not Use With Any Other Labor
Operations Outside Of This Article)
202278E
1.9
Hrs.
2013-2018 F-150 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 L, M And N) (Do Not Use With Any Other Labor
Operations Outside Of This Article)
202278F
2.1
Hrs.
2013-2018 F-150 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 L, M
And N) (Do Not Use With Any Other Labor Operations Outside Of This Article)
202278G
1.6
Hrs.
2013-2018 F-150 4X4: Inspect, Replace Check Valve, Apply Vacuum To Both IWEs
(Both Pass) Road test (Fail Both Sides) Remove Both IWEs, Inspect Wheel Bearing
Splines (Both Pass) Replace Both (2) IWE Clutch Rings (Can Be Claimed With
Operations L, M And N) (Do Not Use With Any Other Labor Operations Outside Of
This Article)
202278H
2.3
Hrs.
2013-2018 F-150 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 L, M And N) (Do Not Use With Any Other
Labor Operations Outside Of This Article)
202278J
1.8
Hrs.
2013-2018 F-150 4X4: Inspect, Replace Check Valve, Apply Vacuum To Both (2)
IWEs (Both Pass) Road test (Fails Both Sides) Remove Both IWEs, Inspect Wheel
Bearing Splines (Fail Both Sides) Replace Both (2) Wheel Bearings And Both (2)
IWE Clutch Rings (Can Be Claimed With Operations L, M And N) (Do Not Use With
Any Other Labor Operations Outside Of This Article)
202278K
2.6
Hrs.
2013-2018 F-150 4X4: Additional Time Use Scan Tool To Active Solenoid And
Measure Vacuum At Both IWEs (Can Be Claimed With Operations A-K)
202278L
0.3
Hrs.
2013-2018 F-150 4X4: Additional Time To Be Used When Vacuum Harness
Replacement Is Necessary (Can Be Claimed With Operations A-K)
202278M
0.5
Hrs.
2017-2018 F-150 4X4: Additional Time To Be Used When TCCM Reprogramming Is
Necessary (Can Be Claimed With Operations A-K)
202278N
0.2
Hrs.
Repair/Claim Coding
Causal Part:
3C247
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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 vacuumintensive engine startup has completed and sufficient vacuum is available to fully disengage
IWEs.
(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 12.5 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.
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• FDRS Vehicles: Command IWE_OUT_ENGAGED = No (False).
(5). Repeat this test on the opposite IWE vacuum supply line.
Figure 4
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 30807A. 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.
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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 20401B.
(2). No - replace the IWE clutch ring. Refer to WSM, Section 308-07A.
© 2020 Ford Motor Company
All rights reserved.
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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