Ford F-150 (2004-2008) :: Popping / Clunking Noise When In 4WD


May 12, 2014

I've read alot of info about the 4WD system on the F150's, and I'm having trouble diagnosing what might be going on with mine.

When I put my truck in 4HI (or 4LO), I get a popping sound that seems to come from the front middle/front drivers side when going at speeds around 20-25 and over. I don't experience any loss in traction (that I can tell) or power, but the popping is very loud and noticeable (passengers can hear it clearly).

My problem is a little different than most, as their issues with popping seem to happen when they are not in 4WD, where mine is only when in 4WD. I replaced the IWE solenoid today (wanted to anyway to get the updated casing/shroud) and the problem stayed. I also disconnected the vacuum lines at the solenoid and drove - no noise. I then kicked in 4WD on the switch, and the noise started, which leads me to think it is not vacuum related.

I am kind of lost as to what may be going on. I would think something where teeth broke, etc. would make noise all the time in 4WD, not intermittently or at certain speeds. The noise sounds almost like popcorn popping. I went up the same hill about a dozen times today, and it happened maybe 5-6 times. I don't hear it often (if at all) with speeds below 20 MPH. I can switch in and out of 2WD, 4HI, and 4LO all day with no issues, as well.

The only modifications to the front end have been a 2.5 inch leveling kit, and the only other issues I notice in the front end is a shaking when on the highway, that seems to go away after a while of driving at the same speed. I recently had a front end alignment, and the only thing the tech mentioned was that I will need ball joints in the next 6-8 months (but he said they weren't bad).

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Ford F-150 (2004-2008) :: Popping Noise Coming From Front End

Alright, so about a month ago I was driving when I heard a terrible noise sounded like a pop can stuck between a bike tire coming from the front end. I figured this was the dreaded noise most folks hear when the 4wd system isn't getting enough vacuum.

It did this for about two days, even after replacing the IWE solenoid, then it just stopped and I haven't heard it since. Me being on the cautious side, I'm a bit worried. I haven't jacked the truck up, but I did (brace yourself) lay under it while my buddy drove slowly over, there was no unusual movement.

Question is, if I had to replace anything, what exactly would it be and how much am I looking at? My warranty will be up in about a month or so and Ford has been less than spectacular with repairs thus far so I'd like to go ahead and fix it myself

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Ford F-150 (2004-2008) :: Popping Noise In Front End When Turning Left

Hear a small pop in the cab when I am turning left pulled left wheel everything looks fine. Ball mount maybe, I don't want to tear into it at this point.

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Ford F-150 (2004-2008) :: 2005 - Popping Noise Coming From The Front End?

I have a 2005 ford f150 supercab 4x4, and around feb I replaced all the ball joints my self, and now recently when back with the wheels turned turned to the left and then put it in drive and turn the wheels all the way right and give it has to take off there is a popping noise that comes from the driver side front wheel and it just does it once I take off and quit . I've looked and everything and cant see anything that would cause this. And know when I put it in park and it rolls forward I can hear a popping noise that sounds likes it coming from the rear end. I had my rear rebuilt, with new pinion bearing and race, a new axle on the pass side with bearing and the shop told me that it the driver side is questionable on the axle but it has new bearing also, they also told me that it needs a carrier case cause it had groves wore in it where the axle bearings wore out so much. at the time I could afford to have them to replace the carrier case. what would cause the popping from the front end and now the popping in the rear end.

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I've got a clunk in the front end....replaced all the ball joints......checked the sway bar......checked the tie rods......can't find anything wrong...... Shocks go bad and clunk???

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The clunking noise started after the 4x4 went out and was really bad for awhile and then went away and has now come back really bad. It sounds like its coming from the front driver's side wheel area and clunks as fast as the wheel turns.(faster = more clunks).

I'm very new to mechanic stuff but enjoy learning and fixing things myself.

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Ford F-150 (2004-2008) :: Clunking Noise From Front Left When Turning Right Only

I have a 2004 2WD supercab. And am hearing a 'clunking' sound when I turn almost full-lock. Below is a summary of what I have experienced so far:

- My truck used to be lowered 2" (below stock) at the front since new. Last month I lifted it (front and rear) and it now sits 2" above stock on new rancho shocks.
- I installed a camber kit and had the front aligned (toe and camber) after the above suspension work.
- The truck drove beautifully for two weeks until one day a 'clunking' sound was heard from the front-left every time I turned left. The alignment also changed as I had to now hold the steering very slightly to the left to drive straight.
- The alignment shop re-did the toe tracking (the camber did not change) and the truck drove great for about a day. Now I can hear the same clunking sound when I turn right and the tracking is again screwed up meaning I need to hold the steering very slightly to the right to drive straight.

What parts are playing up and what may need replacing?

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My service advisor says supposedly the "creaking" noise when letting off the brakes is normal. I told him i really don't believe that lol and asked to test drive another new camry on the lot which is being arranged for tomorrow. In the meantime he says they're gonna look at it either way.

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No noise if turning while NOT under power (coasting). No noise if turning to the right. No noise while driving in a straight line or veering left at a higher speed. Also, I tried to recreate this noise from a dead stop, turning going in reverse, both left and right, and no noise ever.

If in a parking lot, from a dead start, turn wheel left almost one full turn, accelerating slowly I can get the car to make this sound continuously (until I start going too fast beyond my comfort zone).

Have looked under car jacked up several times, nothing obvious. CV axles have minimal play and the boots are in great shape. Suspension parts appear ok.

My gut tells me could be a CV axle, but not certain, and I don't know which side..... something else that could cause this ?

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Ford F-150 (2004-2008) :: With New Tip Installed Now Exhaust Popping?

All I did was cut off the straight section of tailpipe and install a 2.5" inlet, 4" outlet exhaust tip. It sounds a bit deeper at idle and a little louder when I rev it, but when I let off the gas it pops pretty loud.

I remember hearing popping on decel on videos of trucks where aftermarket exhaust/mufflers were installed, but not just from a new tip.

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Issues with rust bubble popping up on the 2004 f150's...

I have some rust bubble's on the rear of the bed right around and under the FX4 sticker...

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