NHTSA Complaint #11716103 — 2017 FORD F-150

On 2/19/25, I was driving to work. Approximately 2 miles from home I started to hear a grinding / humming noise coming from the front differential, like the 4 wheel drive was engaged. I pulled over and confirmed the 4 wheel drive switch was turned off. I backed up about 20 feet, to disengage the 4 wheel drive. I continued on my way. About 3 miles later the noise returned. I could tell the 4 wheel drive had definitely engaged at around 40 mph. Again, I pulled over. When I got under 10 mph, the 4 wheel drive disengaged by itself. This happened 2 more times within the next 5 miles. Had the truck towed to Ford dealership. Technician could not replicate the condition. They performed a Ford TSB (24-2188) Transfer case control module reprogram. Out of caution, I paid them to replace the 4 wheel drive actuator ($445.00 repair). Mileage on vehicle 74354. Problem seemed to be resolved, until 9/13/25. I was driving on a very busy interstate, approximately 60 mph, I hear a loud thump, like I ran over something on the road. Loud humming and bad vibration coming from front end. No place to pull over safely, reduced speed to 45 mph. As I pull to side of the road at about 5 mph, the 4 wheel drive disengages, vibration & noise goes away. Again this happens 3 times in the next 40 miles. (Mileage on vehicle 75529) No issues since - current mileage 77606.