Two problems related to noises during shifting have been reported for the 2004 Lincoln Aviator. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Lincoln Aviator based on all problems reported for the 2004 Aviator.
2004 Lincoln Aviator gears were slipping and would not shift; had it checked and was told the transmission was failing. 2 days later we had to have it towed to the shop because it was stuck in "neutral". Had to replace the transmission at only 63,000 miles. Never had a transmission fail with only 63k miles, all preventative maintenance is kept up on our vehicle. Loud noise at startup and a/c does not work, I believe it is the clutch. No help from Ford even though there are multiple complaints of transmission/power train problems. Also, read that the explorer was recalled for the same problem and that the explorer and Aviator are built with many of the same parts, however, no recall on the Aviator?.
Lincoln Aviator with 54,000 on it and had to fix the transmission, shop said there was some grove on some part in the transmission. Very expensive problems with low miles. Also had a 2004 Mercury mountaineer with 64,000 miles, transmission started to make noises, about a week later it would not shift. Shop said some grove in something in the transmission. Had it fixed for $3,000. Later found out the transmission was out at 10,000 miles before we bought it.