My Aviator ran noise free for the first 7,000 miles, now it exhibits a drivers side buzzing/grinding noise at around 35 MPH. I took it to the dealer, they pointed me to a TSB which stated that the noise was the transfer case calibrating, this was a normal noise. It is not normal. The TSB says something to the effect, that if the AWD system has been idle for too long, ON STARTUP, you may hear this noise. My noise started happening intermittently at 35 MPH while driving around and now it is more consistent. If I drive at 35 MPH, it will do it for miles. If I accelerate through the 35 MPH zone, it won't do it, only seems to do it under light load at that speed.
I've seen where a driveline was replaced, tires rebalanced. I don't believe this is a driveline issue for me. It sounds more like an actuator noise or something not metal, and I can't seem to hear it when I open the window while driving next to a wall or something. Seems to be inside the vehicle and it buzzes the entire driver side of the car.
I'm going to drive it for another week before I take it back and get Lincoln involved. Any ideas from you guys?