Ford - Aviator :: Rattle / Knock Noise Coming From Top Side Of Transmission


Apr 13, 2014

I have a high mileage Aviator - it currently has 162k+ ... I have owned it since 136k, and according to Lincoln's records the transmission was rebuilt/replaced shortly before that ... The truck has run well since we've owned it.

It has developed a noise that I originally thought was an engine problem (bottom end), but I got under it today and took a good listen and it sounds to me like it's coming from the top side of the transmission.

I recorded some sound: 4.6L dohc "rattle" from above transmission - YouTube .....

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Its been in at least 5 times in 2 yrs with cab mount adjustments/shims, cab mount replacements and realignment of the exhaust and brackets. The knock has been there since about day one (I assume anyway, I'm rarely on that side of the cab) and have burned up my 36k warranty, although I'm told i'm good because it is pre-existing.

I keep insisting its in the suspension and keep being told they can't find anything. The mechanic indicated that this is a known problem, but Ford has not put out any service bulletins other than to do the cab mounts and suspension. Has anyone had this problem and found the solution?

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[URL] ....

Is this normal? i don't know where to search anymore to find where the rattle comes from...

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I took it to a local tire/brake place that I have a good bit of confidence. After driving the car, the guy says, "You gotta bad strut!" Called FCP. They sent me a new strut. I installed it and sent the other back. Sounded a LOT better—for about two weeks. Now I am hearing the sound on both sides. I took it to a very reputable Volvo mechanic, I have used since the warranty expired. He drove it, confirmed the sound was not normal. We put it on the lift and he checked everything on the front suspension and was stumped. He said there was nothing wrong with my installation, no problem with the suspension.

Okay, FCP has an unconditional satisfaction guarantee, so I could replace these with a more expensive strut for say $50 more, but is the problem with the struts? I would hate to have to do this installation again and still have the same problem.

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You Tube

So should I take it to the dealer? Or it's normal?

[URL] .....

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2nd check from private mechanic : Definitely sway bar links (he wanted to change all four and sell me new llinks for $100 a pair.)

3rd check from sears service : Sounds like sway bar links, but it might be the struts, I cant say. I dont think its the mounts though(i asked of course). He checks sway bar links and says he doesnt notice any thing different from the ordinary, he thinks its tight. (but also thinks its possible its the problem). Basically left me more confused that i was.

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Shifting is smooth no noticeable problems there. Tranny fluid looks good, not burnt. After further investigation the noise is only present in park or neutral. In drive it goes away. In park it takes a few minutes of warm up for it to begin starting as a light tap tap, eventually working its way up to a clatter once warm. I know the 99 4r100 had some TC issues that sounded like this. It sounds like it's in front of the TC so I'm thinking the flex plate maybe?

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He says the tranny is gone but I am lost on how it shifts perfect except the whine. It does this louder in the lower gears and has a slight knock at idle and disappears when I press the clutch in.

I bought a used tranny already to put in. I also if this is the case and the tranny needs replacing I was told to also do the clutch , should I go stock to save money or go with a different clutch and possibly a LW Flywheel , is it really a drastic power difference?

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