Electronic Shift On-The-Fly (ESOF) 4WD – Intermittent Grinding Noise While Driving – 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator

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NHTSA ID Number: 10222307

Manufacturer Communication Number: TSB 21-2219

Summary

Some 2021 F-650/F-750 vehicles built on or before 20-Nov-2020 may exhibit various electrical concerns and/or various illuminated warning lamps with various diagnostic trouble codes (DTCs) present. This may be due to the battery junction box (BJB) wiring harness contacting the coolant reservoir bracket. To correct the condition, follow the Service Procedure to repair any damaged circuits and secure the BJB wiring harness to the BJB.

 


This bulletin supersedes 21-2076.

This bulletin supersedes 20-2307.

Model:

Ford

2003-2020 Expedition

4WD
2006-2020 F-150
Non-Raptor
4WD
Lincoln

2003-2020 Navigator

4WD

 

Summary

This article supersedes TSB 20-2307 and 21-2076 to update the Issue, Action and Service Procedure.

Issue: Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or 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:

  • One of the following vehicles:
    • 2003-2020 Expedition/Navigator equipped with torque-on-demand (TOD) transfer case (with 4A position on the mode selector switch [MSS])
    • 2006-2020 F-150 (non-Raptor) equipped with TOD transfer case (with 4A position on the MSS) (Figure 2)
    • 2013-2018 F-150 (non-Raptor) equipped with electronic shift on-the-fly (ESOF) 4WD (does not have a 4A position on the MSS) (Figure 1)
  • Grinding/clicking/ratcheting noise from the front axle area

 

Parts

Service Part Number Quantity Description Unit of Issue Piece Quantity
W720613-S439 1 Caliper Anchor Bolt (2015-2018 F-150) 4 2 Per Affected Side
W714743-S439 Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding Noise While Driving - 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator | small light 1 Caliper Anchor Plate Bolt (2013-2014 F-150) 4 2 Per Affected Side
N802827-S100A 1 Front Half Shaft Nut (2016-2018 F-150 Built On Or After 3-Aug-2016) 4 1 Per Affected Side
N802827-S100 1 Front Half Shaft Nut (2013-2016 F-150 Built On Or Before 2-Aug-2016) 4 1 Per Affected Side
W520215-S441 Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding Noise While Driving - 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator | small light 1 Tie Rod Nut (2013-2014 F-150 Built On Or Before 23-Dec-2014) 4 1 Per Affected Side
W520215-S440 Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding Noise While Driving - 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator | small light 1 Tie Rod Nut (2014-2018 F-150 Built On Or After 24-Dec-2014)
W520214-S440 Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding Noise While Driving - 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator | small light 1 Upper Ball Joint Nut (2013-2018 F-150) 2 1 Per Affected Side
7L1Z-3C247-A 1 Per Affected Side IWE Actuator (2013-2015 F-150 Built On Or Before 11-Oct-2015, 2013-2015 Expedition/Navigator) 1 1 Per Affected Side
HL1Z-3C247-A 2 IWE Actuator (2015-2018 F-150 Built On Or After 12-Oct-2015)
1104 1 Per Affected Side Front Hub Bearing – Refer To The Parts Catalog For The VIN Specific Application 1 1 Per Affected Side
W706890-S439 1 Per Affected Side Front Hub Bearing Bolts 4 4 Per Affected Side
HL1Z-3C247-B Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding Noise While Driving - 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator | small light 1 Per Affected Side IWE Clutch Ring Kit 1 1 Per Affected Side
3A788 1 3-Port Check Valve – Refer to the Parts Catalog For The VIN Specific Application 1 1
BL3Z-7A785-A Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding Noise While Driving - 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator | small light 1 Vacuum Lines (2013-2014 F-150) 1 1
FL3Z-7A785-A Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding Noise While Driving - 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator | small light 1 Vacuum Lines (2015-2018 F-150) 1 1
FL3Z-3C125-A Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding Noise While Driving - 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator | small light 1 Vacuum Hose To IWE (2015-2018 F-150) 1 1
W716372-S300 1 Cap (2006-2020 F-150 With TOD Transfer Case, 2003-2020 Expedition/Navigator) 4 2
XG-1-E1 Electronic Shift On-The-Fly (ESOF) 4WD - Intermittent Grinding Noise While Driving - 2006-2020 Ford F-150, 2003-2020 Ford Expedition & Lincoln Navigator | small light As Needed Motorcraft® Premium Long-Life Grease

 

Service Procedure

1. Does the vehicle have a MSS that only includes 2H, 4H and 4L positions (does not include 4A)? (Figure 1)

Figure 1 – Example of MSS without 4A selection

 

(1). Yes – proceed to Step 2.

(2). No – proceed to Step 4.

2. Is the vehicle a 2017-2018 F-150?

(1). Yes – reprogram the TCCM using the latest version of the appropriate Ford scan tool.

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.

(2). No – refer to the 2018 F-150 Workshop Manual (WSM), Section 308-07A Four-Wheel Drive Systems, Diagnosis and Testing, Four-Wheel Drive Systems – Vehicles With: Electronic Shift Transfer Case, Pinpoint Test N for normal diagnostics. Repair is complete.

3. Perform the vacuum system check procedure.

(1). For 2017 vehicles, refer to WSM, Section 308-07A Four-Wheel Drive Systems, Diagnosis and Testing, Four-Wheel Drive Systems – Vehicles With: Electronic Shift Transfer Case Pinpoint Test E. Repair is complete.

(2). For 2018 vehicles, refer to WSM, Section 308-07A Four-Wheel Drive Systems, Diagnosis and Testing, Four-Wheel Drive Systems – Vehicles With: Electronic Shift Transfer Case Pinpoint Test N. Repair is complete.

4. Does the vehicle have a MSS that includes a 4-wheel auto (4A) option? (Figure 2)

Figure 2 – Example of MSS with 4A selection

 

(1). Yes – proceed to Step 5

(2). No – this article does not apply. Refer to the Workshop Manual (WSM) for normal diagnostics.

5. Locate the vacuum supply line between the source vacuum and the IWE check valve. Refer to WSM, Section 308-07A. (Figures 3-4)

 

 

6. Remove the vacuum supply line.

7. Install the vacuum caps at the IWE check valve and the vacuum source.

 


2 Affected Products

Vehicles

MAKE MODEL YEAR
FORD F-650 2021
FORD F-750 2021

 


1 Associated Document

Manufacturer Communications

22-2219
20 June 2022

https://www.nhtsa.gov/recalls?nhtsaId=10222307

MC-10222307-0001.pdf 336.571KB

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NHTSA ID Number: 10214754

Manufacturer Communication Number: TSB 22-2219

Summary

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure to remove and cap the vacuum supply line or to reprogram the transfer case control module (TCCM) and replace any worn vacuum and/or IWE components.

 

1 Associated Document

Manufacturer Communications

22-2219
20 June 2022

https://www.nhtsa.gov/recalls?nhtsaId=10214754

MC-10214754-0001.pdf 176.182KB

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NHTSA ID Number: 10189784

Manufacturer Communication Number: TSB 21-2076

Summary

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. ESOF can be identified as it does not have a 4WD AUTO (4A) position on the mode selector switch (MSS). 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.

 

1 Associated Document

Manufacturer Communications

21-2076
17 March 2021

https://www.nhtsa.gov/recalls?nhtsaId=10189784

MC-10189784-0001.pdf 746.108KB

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NHTSA ID Number: 10181917

Manufacturer Communication Number: TSB 20-2307

Summary

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IWE). To correct this condition, follow the Service Procedure steps to remove and cap the vacuum supply line.

 

1 Associated Document

Manufacturer Communications

20-2307
15 October 2020

https://www.nhtsa.gov/recalls?nhtsaId=10181917

MC-10181917-0001.pdf 406.947KB

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NHTSA ID Number: 10181915

Manufacturer Communication Number: TSB 20-2278

Summary

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.

 

1 Associated Document

Manufacturer Communications

20-2278
15 October 2020

https://www.nhtsa.gov/recalls?nhtsaId=10181915

MC-10181915-0001.pdf 730.654KB

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NHTSA ID Number: 10171859

Manufacturer Communication Number: TSB-20-2028

Summary

Some 2013-2018 F-150/Expedition/Navigator vehicles equipped with 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.

 

1 Associated Document

Manufacturer Communications

20-2028
11 February 2020

https://www.nhtsa.gov/recalls?nhtsaId=10171859

MC-10171859-0001.pdf 704.113KB

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NHTSA ID Number: 10176835

Manufacturer Communication Number: TSB 20-2189

Summary

This article supersedes TSB 20-2028 to update the description of Labor Operation D. Some 2013-2018 F-150/Expedition/Navigator vehicles equipped with 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.

 

1 Associated Document

Manufacturer Communications

20-2189
01 June 2020

https://www.nhtsa.gov/recalls?nhtsaId=10176835

MC-10176835-0001.pdf 823.603KB

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NHTSA ID Number: 10170914

Manufacturer Communication Number: TSB 20-2013

Summary

Some 2013-2018 F-150/Expedition/Navigator vehicles equipped with 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.

 

1 Associated Document

Manufacturer Communications

20-2013
17 January 2020

https://www.nhtsa.gov/recalls?nhtsaId=10170914

MC-10170914-0001.pdf 715.75KB

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NHTSA ID Number: 10164426

Manufacturer Communication Number: TSB 19-2252

Summary

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 replace the worn vacuum and/or IWE components.

 

1 Associated Document

Manufacturer Communications

19-2252
22 August 2019

https://www.nhtsa.gov/recalls?nhtsaId=10164426

MC-10164426-0001.pdf 491.036KB

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NHTSA ID Number: 10149748

Manufacturer Communication Number: TSB 18-2273

Summary

Some 2013-2018 F-150/Expedition/Navigator vehicles may exhibit an intermittent grinding noise coming from the right or left IWE area in 2WD mode. Follow the Service Procedure steps to correct the condition.

1 Associated Document

Manufacturer Communications

18-2273
17 September 2018

https://www.nhtsa.gov/recalls?nhtsaId=10149748

MC-10149748-9999.pdf 308.073KB

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