It's a metalic noise when put into gear. Stops for a moment as it shifts to next gear. Goes away when it reaches final drive gear. There is a vibration while shifting as well.Had a good mechanic friend state--Thinks it's a bolt working loose, holding the flex plate. Had lincoln Dealer car was purchased from check this but never found the problem.I understand it's been a large problem for Ford. , This started around 60000 and now 120000.Can't seem to trust Dealers service, or afford their charges. What's the best thing to do?? Can I Expect any help from FORD?? --Or??? Thanks for any help-- I'm a senior with very limited funds!!!

I'll be honest with you, this problem varies depending on the configuration of the motor. From what you are telling me however this is most likely not a bolt working loose. If you have a transverse mounted motor, the motor is mounted sideways with front wheel drive (The common V-6 and 4 cylinder configurations) this is likely to be the differential but could be the flex plate mounting between the two since there is a plate mounted between the motor and the Transmission that joins the two for balance. This is most commonly damaged and overlooked if you have had front end damage or hit some really bad pot holes. Now, if this is the big V8 with rear wheel or 4 wheel option installed the most likely problem is one of the differentials and if the noise is coming from the front that would be the front differential. You can get a grinding sound if the gear boxes are low or empty on fluid, CV joints are bad, Front end bearings are bad (sounds louder on the left or right side of vehicle than the other) All of these need to be checked. For that matter so do the brake calipers if a caliper is applying uneven pressure or not releasing correctly or a rear pad came free like I had where the pad came free in teh drum you will get this type of sound. I know these came in both 4 wheel and 2 wheel options and as I said the configuration of that will tell you where to look. The problem Ford had is very similar to the problem GM had with the rear differentials in some of their suburbans with the gears not meshing correctly and it being very difficult to get that alignment just right. Unfortunately, if the alignment inside the differential is just right you will get that grinding sound, as my son found out after going through months of repairs. I finally picked up a rear differential for him and installed it to get rid of the problem. But it was actually from a dodge.

Hello Ray, i don't blame you for not trusting the dealer. It does sound like the problem is loose converter bolts or a cracked flywheel---it's hard to say without actually hearing the noise, or driving the car. I would suggest you get a second opinion from another local shop that has a good reputation. With your car up on a lift, the inspection cover, under the bellhousing can be removed and the flywheel-ring-gear can be seen, also the outside of the torque converter...If it's loose, there will be movement in that area....If the converter bolts are found to be loose, the flywheel will have to be replaced because the bolt holes will be elongated.
However, the price to repair and replace these parts is no where near 6000. For half of that, the complete, transmission can be replaced.

Also note, There was a maintenance recall in 2004 for 2002-2004 models...Ford released a bulletin, and claimed they notified owners, about putting in the wrong transmission fluid into 750,000 of their SUV's ...You need to mention this to your dealer, if they act like they know nothing, call Ford customer support...have your VIN number ready, it takes awhile to get a live person..there's a chance they could help you with repair costs.
800-392-3673

I hope this helps Ray...reply back if you need further assistance.

Hi

If your transmission makes a metallic clunking noise or vibrates while shifting gears during normal driving, then the transmission mounts may be loose. Check that area to fix the problem.

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