For the last 12 months or longer we have been dealing with an intermittent starter grid on our 00 expedition. I have replaced the starter 2 times, the last time was with a new (not rebuilt) starter and the starter relay on the firewall with a ford motorcraft one. As soon as it did it again we stopped driving it and I pulled the tranny and replaced the flex plate. It had an area about 6" long that had the teeth ground down about half way. NOT a fun job.

We have been driving it for a few weeks now without a problem. Yesterday my wife says it ground again when she tried to start it. It started fine on the second try.

I am wondering if anyone has had the actual ignition switch cause this. It's the only other thing I can think of.

 

Its possible the starter isn't square with the flywheel. This keeps the teeth from fully engaging and eventually you will get grinding.

 

I have the same issue with my 04 expedition. I have been looking for a thread on it for a while now. it's interesting to hear that you have changed the starter and flex plate(?) and still have the issue. I'll save this thread and check back in if I get some helpful info.

It's aggravating, concerning and sometimes embarrasing. But, a few months ago outside a high falutin' restaurant, we were parked in the very front spot, surrounded by folks having a nice quiet meal. when all of a sudden 'GRRRRRRIIIND!!!'. People were scrambling everywhere, coffee flying, chairs tumbling. My wife and I laughed ourselves to tears. I felt bad for the people, but it was an unforgettable moment.

 

Been doing a lot of work to this crazy rig for different issues but the starter grind still persists.

We have replaced the starter multiple times, the flex plate, starter relay on the firewall and the ignition switch. The only thing left is the battery cables. I hope to do those after the new year. Hopefully its a bad ground or connection on one of them.

 

Thanks for the post. I read something in a related post about the ignition switch on the steering column. It's hard for me to imagine how that could be directly related to the starter grind. But I have noticed that if I turn the wheel a bit when it grinds the first time, it starts right up. Just food for thought.

I also have an intermittent rattle that seems to come from the front of the transmission. Sounds like a metal plate jiggling somewhere. But, everything is buttoned up tight under there. So, its just a mystery. I wonder if it is related to the starter engaging.