i know this is the taurus section, but i figured it would get a little more attention than the freestar section.
we own a 2004 freestar van with the 3.9 and ax4n.
one day while my girlfriend was driving it she told me about a noise she heard while pushing on the throttle, kind of a popping sound. well we had also just received the recall notice for the torque converter and i assumed it was related so we had the recall done.
the noise was still there. so i just thought to myself that it could be the CV axles, so i waited till i had an empty spot in my shop that i could bring it in and do some service work. over the next 2 weeks the noise got a little worse and you couldnt give much throttle at all before the popping noise happened.
so yesterday i brought it into the shop and checked the axles, they were fine. so i had a coworker get in the driver seat and power brake it some to duplicate the noise and so i could see if i could spot anything under the van. well, while we where doing that it did the noise pretty loud and something let go. the van would no longer move forward....
i decided to investigate myself instead of bringing it back to the dealer. i dropped the tranny to check the converter teeth to see if they were stripped, they were not. so, i tore down the transmission thinking maybe we grenaded the spider gears. well, ive got this thing completely torn down and the only thing i can find is about half of the material on the "coast band" was worn off and there were some heat spots on the back side of the band.
now, while i am pretty competent with a wrench, my experience with automatics internally is pretty small.
now my question is, anyone have any idea of what could have been causing the popping noise? and led to the ultimate failure? is it all all possible that the damaged coast band could have caused this?
any help is greatly appreciated. this is a bad time of year to half to buy a new transmission.