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The actuator isn't sold separately, it's part of the front intermediate axle

Currently waiting for the front axle assembly to come off backorder

Mine is covered under warranty, so unless you have over 60k miles i would think yours would be covered, it's a single part, if you look at one of my previous posts there is a screen shot from the parts catalog that shows the assembly.

F-150s used a vacuum actuator in the IWE. They use vacuum to hold the actuator open but when you lose vacuum those actuators default to engage the hub. Newer F-150s use an electronic version of the IWE. The system in the Bronco uses a dog clutch between the differential and the axle to decrease...

Pretty straight forward to test it out, the tech just has to reach up on top of the actuator and unplug the connector, road test and see if the vibration is gone, this will however trigger a wrench light and a "Service 4WD" warning message.

UPDATE: THE NOISE/VIBRATION IS GONE!!!!!! Got it in the shop today, tested the theory on the faulty 4WD disconnect by unplugging the actuator, road tested 20 miles, no more noise. So, for now I will just ignore the wrench light on the dash and wait for the parts to arrive.

Will do

Not yet, she goes under the knife Tuesday to isolate the cause, unfortunately I checked the availability of the axle/disconnect assembly and it is on backorder with no ETA, which means I'll have to slog through COPIS to get them to redirect a part from the assembly line to me, perks of working...

Possibly related question, for those of you who are having this issue. What axle ratio do you have? Do you know if you have an electronic front axle disconnect (see the pictures for comparison, top picture shows the disconnect)

So update from the tech line, they are thinking it may have something to do with the 4WD disconnect either not full disconnecting or connecting, have an interesting method to test for this which involves temporarily running my Bronco as the only front wheel drive bronco out there, they have to...

SMALL UPDATE: The service department has opened a Techline case for this issue, I think my Bronco might hold together long enough to diagnose the issue, it seems like every time they try to bring it in to pin point the problem they find something else wrong with it, one time the upper control...

Already had the transfer case replaced so I'm assuming the tech torqued all of the new bolts that he put in.

Yes, that sounds exactly like what I am hearing, does the noise go away when you engage 4WD

Going back in the shop Tuesday or Wednesday of next week 🤞 hopefully will have an answer then!

Current 7 day forecast in Central NY, nothing out of the norm for us though, just a little 37 degree temperature drop

That was my initial thought was a tire issue but when it starts and stops depending on the 4WD that threw that theory out the window

Just wondering if anyone else has come across this issue with their Bronco, or if any technicians on here have heard of this. Dealership has been trying to find the cause of this vibration, noise started out of nowhere while driving at highway speeds, it starts out at a pulsing vibration...