Ford IWE (Integrated Wheel End)

Actuator pictures

This what it looked like when I removed it but....

The problem is that it isn't supposed to be in two pieces. 

If you look towards the top you see the lighter colored plastic
broken loose allowing locking sleeve to stay in locked position.

What was making the noise was that the gear part was simply floating

around when not in 4 wheel drive. 

The circled area is where the parts were attached together at one point.

The plastic was simply rubbing inside the main part of the actuator

all the time when in 2 wheel drive.

Once vacuum was removed it allowed diaphragm to place pressure on it, quieting it.

Used the Dorman Actuator available for less than $100.00.

New Actuator looks like this

The large vacuum hookup is for vacuum supply and the other is a vent.
The top side of this picture is the side that goes on the axle shaft.
The three screws bolt into the wheel knuckle.

You can see the geared area which is only about 1/2" wide that is used to
lock the two gears together when engaged.

This is the side that is against the hub. The tan plastic is
basically a sling for the gear sleeve and is supposed
to be attached to the diaphragm which pulls it away from
the hub when in two wheel drive.

One has to remember that the default position is
out against the hub when engine is off and no vacuum being applied.