Grind or popping noise at slow speeds

[mq019]

Did you have this noise too, is that why you took yours in? Or how did you know there was a problem with yours?

Hard to tell if it sounds exactly the same as what you have there in your video.

If its a CV join issue, you'll hear it more and more as it gets worse (it gets louder), and will hear it more when accelerating and if you make a tight turn (binds up the CV knuckle).

After I started noticing it on mine, I took my truck to a quiet parking lot, rolled all the windows down, and took some tight turns, and did some acceleration from a stop - you should hear it clunking and/or kind of a grinding noise - I thought for a while that I had gotten some gravel behind the caliper or something that was rattling around.

took it to the dealer and they found the issue right away - the only problem was parts availability (which makes me wonder if this might be a more common issue than we know since I don't understand why they wouldn't have some in stock somewhere in the country). Ford EV folks were involved and paying for my loaner the whole time, it just took a while.

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[Bigisland Guy]

I had the issue on my old 23 and the TSB resolved it, but mine never popped like yours.

 

[TaxmanHog]

POST ONE has the PDF of the TSB

 

[chl]

POST ONE has the PDF of the TSB

Oops I missed it, my bad.

 

[dpwmc93]

I did some research online and found this...

Based on the description of low-speed, intermittent grinding/popping while turning or backing up, this issue is commonly related to front differential actuator vacuum issues (IWEs), front CV axles, or steering rack binding. Given the leveling kit and larger tires, the CV angles are increased, making it likely a binding joint or vacuum-related issue.

Potential Causes and Fixes:

• IWE (Integrated Wheel End) System: On Ford trucks, a failed IWE check valve or cracked vacuum line can cause partial engagement of the 4WD hubs at slow speeds, resulting in a grinding sound. This is common with leveling kits and is often mistaken for a transmission or bearing issue.
• CV Axle/Joint Damage: The grinding/popping while turning at slow speeds strongly suggests a damaged or binding CV joint.
• Steering Rack/Turn Stops: If the sound only happens at full lock, it may be the tires rubbing on the sway bar/control arm, or the steering rack itself making noise, though your tire shops' feedback makes this less likely to be just a simple rubbing issue.

Recommended Next Steps:

1. Try a Different Dealer: Take your videos to a different dealership that has experience with lifted/leveled trucks.
2. Request Specific Checks: Ask them to check the IWE vacuum pressure and perform a "vacuum test" on the hubs.
3. Inspect CV Joints: Have them inspect the front CV axles for torn boots or play.
4. Reference TSBs: Mentioning Ford Technical Service Bulletins regarding "IWE grinding" or "suspension clicking" can help focus their diagnosis.

 

[chl]

My 2001 Ford Ranger made the same noises.
They happened when I turned - the rubber boot(s) around the CV joint(s) had worn out and torn.
The Ford dealer repair was not cheap, around $1,000, probably replaced both I don't recall.
The truck was not high mileage but was 13 years old at the time.

 

[Heliian]

Being suspension related, could OP jump around in the frunk/bed to test diagnostically to help narrow the cause?

Not really, that that only works for more obvious problems.

 

[mq019]

I did some research online and found this...

Based on the description of low-speed, intermittent grinding/popping while turning or backing up, this issue is commonly related to front differential actuator vacuum issues (IWEs), front CV axles, or steering rack binding. Given the leveling kit and larger tires, the CV angles are increased, making it likely a binding joint or vacuum-related issue.

Potential Causes and Fixes:

• IWE (Integrated Wheel End) System: On Ford trucks, a failed IWE check valve or cracked vacuum line can cause partial engagement of the 4WD hubs at slow speeds, resulting in a grinding sound. This is common with leveling kits and is often mistaken for a transmission or bearing issue.
• CV Axle/Joint Damage: The grinding/popping while turning at slow speeds strongly suggests a damaged or binding CV joint.
• Steering Rack/Turn Stops: If the sound only happens at full lock, it may be the tires rubbing on the sway bar/control arm, or the steering rack itself making noise, though your tire shops' feedback makes this less likely to be just a simple rubbing issue.

Recommended Next Steps:

1. Try a Different Dealer: Take your videos to a different dealership that has experience with lifted/leveled trucks.
2. Request Specific Checks: Ask them to check the IWE vacuum pressure and perform a "vacuum test" on the hubs.
3. Inspect CV Joints: Have them inspect the front CV axles for torn boots or play.
4. Reference TSBs: Mentioning Ford Technical Service Bulletins regarding "IWE grinding" or "suspension clicking" can help focus their diagnosis.

Its definitely not an IWE issue - thats an ICE issue. These trucks dont have that system -they're full time 4WD/AWD

 

[Kyle]

After watching the videos, I second the suggestion that this is CV axle (halfshaft) related.

 

[chuck27p]

Update: Took it to Ford. Here's what going on apparently (fingers crossed, I pick it up today and will drive it for a week and hope the noise is gone as they say).

"Alignment adjusters loose causing flex noise while moving and turning. Aftermarket caster/camber adjusters and shocks. Torgued lower control arm bolts and lower shock bolts. Some noise from front skid plate from impact, corrected bend too."

If this is correct, then two off road shops didn't torque bolts to spec. Easy fix. Ford also has an alignment rack and they did the alignment afterwards and sent me the report, which is great, most shops around here don't have that and do it by hand.

With a little luck, everything should be back to normal. I'll report back in a few weeks.

 

[wapple24]

I have had a squealing noise when turning the wheel, twice now. Dealer is replacing my driver’s side front control arm for the second time. Thank goodness for extended warranty.

 

[chuck27p]

It's been a few months and I wanted to update this post in case it helps someone in the future. After a few more trips to the dealership, the popping noise I was getting (mostly on full left turns, like a uturn) was caused by the cam bolts. Over time they would ever so slightly come loose. I've had them tightened 4-5 times and then noises go away. No other issues.

I noticed that bolts showed signs of slippage as well. Here's a pic I took BEFORE I upgraded the bolts.

I decided to upgrade the bolts to these SPC HD Alignment Cams [F-150]. Bought them myself and had Ford install them. The dealership said they'd do it and they have an alignment machine, which my local shop doesn't have, so I ended up just having Ford do it. Now the bolts are locked in place with a little hole that is drilled so the eccentric bolts can sit flush on BOTH sides. Since then no issues.

I have shocks up front a 2" lift to level the truck, and at work where I part I have to turn all the way left and hit a dip in the pavement every day, so I'm not sure if they just slightly loosen under the load over time, but hopefully this new setup fixes the issues for good.

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