About once a week when I crank my truck I get an awful metal-on-metal crunch sound. I try again and it starts right up. This has been happening for a year now - I've never had it looked at because I knew it would be expensive and because I can't predict when it's going to happen.

Truck is a 2004 with 5.4 engine.

Anyone else experience this (my friend with an '05 has)? What is it?

 

Sounds as if the starter bendix is not fully engaging in the flywheel. This can destroy the fly will and it will be REALLY expensive to replace.

 

Man mines been doing it for about 5 years now and no mechanic or even ford could figure it out and about 6 months ago my wifes 05 started to do it. Good luck and let me know what you do to fix it.

 

x2. Get it looked at now or it will cost you more down the road. Nothing ever gets less expensive to fix if you ignore it.