> Now I have figured out that only pops when the outlet is touching the metal box.
Are you saying it trips when nothing is plugged in? Is there a separate ground wire to the GFCI? Are you sure the ground wire is actually tied to ground? Are you feeding any outlets downstream of the GFCI?
If the GFCI and box are both properly grounded, then it shouldn't make any difference if the GFCI is in contact with the box or not. My assumption is one or the other is not actually tied to ground.
GFCIs work by sensing a difference in voltage between the hot and neutral conductors. You can have current running through ground all day without tripping the GFCI, as long as that current isn't originating in the protected circuit. Somehow, when you touch the GFCI to the receptacle box, you're completing a path to ground. I'll bet you will read voltage between the box and the GFCI when they're not in contact.
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