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Grinding Front End Noise at Low Speeds. Dealer wont do anything even under warranty!!!

Just had mine in the shop for this issue as well as another. While the other issue was handled, the tech tried to tell me that my tires were choppy and the noise I am hearing was from them. Crazy
 
Just had mine in the shop for this issue as well as another. While the other issue was handled, the tech tried to tell me that my tires were choppy and the noise I am hearing was from them. Crazy
Mine just told me it's due to my suspension being worn, which caused the tires to cup causing the noise. Not covered under Ford Protect as it is a consumable item wearing at about the right time.
 
My 2022 is in the shop for the same thing right now. It doesn't happen all the time though and hard to replicate. Happens more on cold mornings but still happens at other times. Told the shop about the TSB (there's one for 2024 for 2021-2024 models and an updated one for 2025 that covers 2021-2025 models), and they said my VIN didn't return any TSBs for it so they didn't even check out the IWE.

In other news though, in other forums people say they switch to 4H/2wd back and forth like 20-50 times and then it hasn't happened since. Going to try that when I get my truck back later today.
 
Dealer "fixed" the IWEs om my 2015 Platinum 3 times,,, they were starting to grind again when I traded it off @ 60K miles.
There is an aftermarket IWE eliminator kit..I've no experience with it though.
 
I just had the exact same issue on my 2022 402A with Torsen and 39k miles. It would go away when switched to 4A. I even got it on video where you can clearly hear it. It also had a vibration under heavy acceleration that I couldn't figure out. When changing the oil, I noticed the passenger side front axle shaft seal was leaking. It was dripping. I took lots of clear photos and wiped it clean because I didn't want it dripping on my driveway. Took it in the next day and after keeping it for 3 days they told me the seal wasn't leaking bad enough to get it covered and said they couldn't replicate the griding eIWEs. I opened a case with Ford that night and took it back the next day as it was now grinding worse than before. They told me it was my tires too but couldn't explain why it went away when switching it into 4A. They told me the TSB didn't apply to mine either. They finally agreed to replace the leaking shaft seal but dind't replace the eIWEs stating the same reason. They also informed me the passenger side strut was blown and wanted $1400 to fix it. I told them a good dealer would warranty that out of good faith since it was just out of warranty by a couple weeks and 3k miles but they refused. No idea what caused the strut to fail. I've not done anything to stress the suspension enought to blow the seals. I picked it up and immediately took it and got new tires because I did need a set. Got home to look at the strut and discovered they tore the CV boot and all the grease was slung all over the inside of the wheel. Went back in the next day for a 3rd time and they agreed to replace the axle. To my surprise, when I picked it up they had repaced the eIWEs too. Drives as smooth as butter now. No vibration either.

I just don't understand why they fought replacing the actuators when it was verbatim what the TSB stated. Hopefully that will be all the issues for a long time. Ordered some new struts and will replace those myself.
 
I just had the exact same issue on my 2022 402A with Torsen and 39k miles. It would go away when switched to 4A. I even got it on video where you can clearly hear it. It also had a vibration under heavy acceleration that I couldn't figure out. When changing the oil, I noticed the passenger side front axle shaft seal was leaking. It was dripping. I took lots of clear photos and wiped it clean because I didn't want it dripping on my driveway. Took it in the next day and after keeping it for 3 days they told me the seal wasn't leaking bad enough to get it covered and said they couldn't replicate the griding eIWEs. I opened a case with Ford that night and took it back the next day as it was now grinding worse than before. They told me it was my tires too but couldn't explain why it went away when switching it into 4A. They told me the TSB didn't apply to mine either. They finally agreed to replace the leaking shaft seal but dind't replace the eIWEs stating the same reason. They also informed me the passenger side strut was blown and wanted $1400 to fix it. I told them a good dealer would warranty that out of good faith since it was just out of warranty by a couple weeks and 3k miles but they refused. No idea what caused the strut to fail. I've not done anything to stress the suspension enought to blow the seals. I picked it up and immediately took it and got new tires because I did need a set. Got home to look at the strut and discovered they tore the CV boot and all the grease was slung all over the inside of the wheel. Went back in the next day for a 3rd time and they agreed to replace the axle. To my surprise, when I picked it up they had repaced the eIWEs too. Drives as smooth as butter now. No vibration either.

I just don't understand why they fought replacing the actuators when it was verbatim what the TSB stated. Hopefully that will be all the issues for a long time. Ordered some new struts and will replace those myself.
Out of curiosity, what dealer did you take yours too? I took mine to Two Rivers since it's half a mile from my house, but after being there a week and a half without them looking at it, I brought it to Bates in Lebanon. They had no interest in looking at the IWE TSB or watching the video I had where you can hear the sound, and then just said if they can't replicate it they can't do anything about it. Which is frustrating because the TSB itself said it's INTERMITTENT which means it's random and you can't always hear it.
 
well update. Got the case number with ford and was annoying enough to get them to get it on schedule. Sometimes you have to be that guy. What I didn't expect is that is they had to replace an axle as well which is kind of wild considering they had the truck in for the initial evaluation and it was perfect according to the previous report....
 
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