I have had a noise that sounds completely out of place coming from the underside of my vehicle for quite some time. I've had it in to the dealer three times for service and twice for ride-alongs to regarding the issue and they always list it as unable to reproduce/performing to manufacturer spec. I think I read another thread with a similar problem on this or another Ford forum, but I am unable to find it.
Basically, the noise sounds like a grind or crunch when I let my foot off the accelerator to slow down and then accelerate again without the transmission downshifting. Examples of this occurring are on a highway merge ramp if I let off the gas while waiting for a safe spot to merge and then give it gas to enter the flow of traffic. Another example is going around a slight corner. If I let off the gas to reduce speed slightly and then accelerate out of the turn, it makes the noise when I hit the gas. This is very noticeable when i DO NOT push the pedal to the floor, but simply accelerate normally. This does not occur if I come to a complete stop like at a stop sign or any other situation where I slow down enough for a downshift to occur. This only occurs when the vehicle is in motion.
The noise is noticeable to passengers, as well as myself when I am driving.
I am currently out of the bumper to bumper warranty period, but still in the drive train warranty period, but barely. I'd like to find someone with a good idea of what this might be so I can point my delaer in the right direction instead of simply saying it is making a noise. Documentation like a TSB would be extremely helpful, but just a solid idea of what it might b would be more helpful than what I am able to tell them.
The best description I can think of is a bad universal joint I had on an old Ranger. That was more of a clunk than the noise I'm hearing in my expedition, but the timing after acceleration seems to be about the same. The noise I am hearing sounds more like metal rubbing on metal as opposed to metal striking metal.
Hopefully, someone can provide some ideas based on the limited information I can provide. They have flashed the various components to the latest versions, but there was no resolution there. If any other information would prove beneficial to determining what this noise might be, please don't hesitate to ask. Thank you.