My 2010 Edge SE developed a similar problem at about 30K miles that increased over time. At 33K miles the Dealer evaluated the sound and performed an extensive rebuild of the output section of the trans documenting excessive and unusual wear patterns and metal build up on the scavenger magnet. Multiple mechanical parts were replaced.
As a result of the repair a secondary problem emerged as a random high pitch rotating metal on metal squealing at engine RPMs of about 1500, observed while driving away after pickup of the car. I returned to the dealer and test drove the car with the Trans Technician demonstrating the condition. I was later able to record audio and video of the condition on my Ipad. I returned the car to the dealer along with the recordings. After several days of evaluation, the dealer declared that they were unable to duplicate the problem and therefor no further action was warranted or authorized. I opened a report with Ford Customer Service and pretty much got the same answer.
So far, no one has been able to explain or even offer a plausible theory as to the source of either noise and the potential implications as to the current safety an serviceability of my vehicle. Yes, the original noise is still present, just reduced in audible volume. The secondary noise has not repeated for the last 200 miles or so.
Does anyone have a similar experience and/or any ideas as to the source of these conditions? What can be done to ensure that the Trans is intact and safe for the road?
AJK
