LOUD Grinding Noise off and on...

[bmp0014]

I have a 2005 Ford Expedition Limited 4x4 that is absolutely amazing as far as the ride goes but it does have it's issues.

1. Just recently I switched my expedition into Auto 4x4 then into 4L then into 4H (just making sure it switched properly). After doing so my father drove around in 4L slowly around corners. It makes a rubbing noise when turning left or right, but when going straight there was no noise.

2. After that we put it back to 2H and decided to take it for a spin on the interstate. As we were driving back it started making a LOUD grinding (metal to metal) sound. It was almost like the sound of a skill saw. It would make the noise for a few minutes then quit. We noticed the battery meter would drop and go back to normal, the radio would shut off and the a/c would shut off for a split second...then the noise would stop. We put it in park and the noise came back until we took it out of park and drove it for a bit.

After driving it to the mechanic, the noise stopped all together. (GO FIGURE). I turned off the expedition for a few minutes, started it back up and drove it home and the noise started again off and on. It's not constant.

The power drainage leads me to believe the alternator is about to go out....please give me your input on these. I have it at the local Ford dealership so they can check it out....but would like to know what I may be facing or if any of you have had this issue. It's odd because even with the loud noise, the engine and transmission acts totally normal...nothing is shaking, nothing seems wrong w/ the engine or tranny. I do have an extended warranty on this....but again, I am impatient with this and would like to know your input.

Thanks a lot for any help!!

 

[toms89]

Did you drive in 4 low turning on the pavement? Ouch..

When turning the front wheels travel more distance than the rear and there is no differential between front and rear. Something has to give...hopefully your tires just spin or scrub. Or else you can damage one of the many 4wd components. Half shafts, differential, transfer case, driveshaft..etc.

Since your describing grinding noise Im guessing you may have stripped some splines or damaged some 4wd component.

Never drive in 4 high or low unless your offroad or in measurable snow on the road. Use A4wd only on dry pavement.

 

[toms89]

Did the power issue occur at the very same time?

Did you stop and put it in neutral to get it out of 4-low? Did you hear the clunk of it disengaging?

Then again the noise could be completely unrelated to the above actions. Maybe you have a bad bearing on one of the accessories or idler/tensioner pulleys? This could explain the charging issues better.

 

[bmp0014]

Did you drive in 4 low turning on the pavement? Ouch..

When turning the front wheels travel more distance than the rear and there is no differential between front and rear. Something has to give...hopefully your tires just spin or scrub. Or else you can damage one of the many 4wd components. Half shafts, differential, transfer case, driveshaft..etc.

Since your describing grinding noise Im guessing you may have stripped some splines or damaged some 4wd component.

Never drive in 4 high or low unless your offroad or in measurable snow on the road. Use A4wd only on dry pavement.

Yeah, I figured that. My Dad is hard headed, he was driving it hard around corners. Didn't make the grinding noise until after that. So maybe it's something to do with the 4 wheel f drive.....thanks for the reply, I'll fill my mechanic in on that.

 

[bmp0014]

Did the power issue occur at the very same time?

Did you stop and put it in neutral to get it out of 4-low? Did you hear the clunk of it disengaging?

Then again the noise could be completely unrelated to the above actions. Maybe you have a bad bearing on one of the accessories or idler/tensioner pulleys? This could explain the charging issues better.

Yes, my father disengaged the 4wd by doing that. After that we took it on the interstate and the loud grinding noise started off and on. The rubbing noise has been ongoing of and on before we messed with 4wd. That only happens when turning and only for a second. It's like it is traction control but on smooth pavement....

 

[uhaul]

My Ford mechanic buddy told me just yesterday that on the passenger side of the firewall (near battery) the little black --doohicky-- shorts out from water running off top of cowl and dripping on it. he said it makes the front hubs engage and disengage causing a growling sound on and off. so check that thing.

 

[bmp0014]

My Ford mechanic buddy told me just yesterday that on the passenger side of the firewall (near battery) the little black --doohicky-- shorts out from water running off top of cowl and dripping on it. he said it makes the front hubs engage and disengage causing a growling sound on and off. so check that thing.

Oh really? It is at my local Ford dealership. They are trying to duplicate the noise but said they can't. He recommended me keeping it overnight there so he can try and duplicate it before contacting the extended warranty company I have to approve work to be done.

He found that the clutch packs in the rear are going out (which is why the rubbing feeling when taking corners slowly). And for the diesel engine sound (ticking) he said the passenger side cam phasers are making that noise, so they need to be replaced.

SO, we have 2 of 3 issues fixed. We are just waiting for that noise to come up again so he can see where it's coming from. He's checked a lot of things....but didn't see anything wrong with those. I don't think he checked the black deal beside the battery...I'll let him know of that because I did notice my accessories (radio & a/c) would power off for a second when it makes that noise then come back on. But it doesn't reset itself.

Thanks for the info guys! I'll definitely let him know of those possibilities.

 

[bmp0014]

I just remembered....the grinding noise continued when we put it in PARK so it has to be something that is turning continuously...not only when in drive. It's with Ford though, so they should be able to eventually duplicate it and if they can't....it must not be that major of a deal...if it happens again, I'll drive it to the dealership and have them find the noise.