My truck has a noise that is driving me nuts!!! It occurs after the truck has warmed up, only while driving at very slow speeds/RPM's... As in while driving in a parking lot, just coasting, then you BARELY get on the gas, as in only 1000 RPM... At that moment there is a rattle that sounds like it's coming from the engine compartment. I can usually duplicate the problem as much as I want to at that speed/condition.

I just took it to the dealership last week. They even had me test drive it with the tech. Fortunately, I was able to make it produce the rattle during the test drive. Right away the tech said it sounds like its exhaust-related. Anyway, I got a call from the dealership a day later; the SA said that they were unable to find the rattle, and that the Ford helpline said not to attempt any further repair until/unless the noise gets louder.

Needless to say, I can't wait until it gets louder... Anybody have any idea what it could be?? On several occasions I've crawled under the truck to check everything out. Nothing seems loose. What really sucks is that I can't duplicate the sound while the truck is stationary. HELP!!!

 

My 05 has a sim noise.To me it sounds like its under the passenger floor board area.I took it to a muffler shop a friend owns and we spent about 1 1/2 hours looking for the noise and could not find it either.No pipes are loose none of the heatshields were loose but my noise is just getting louder by the day.I took it to the dealer and was told the same thing.Its going back to the dealer next week its getting on my nerves big time.I was told that they had some issues with the cats.He said some were being replaced to get rid of the noise but who knows.Mine only makes the noise if its moveing it wont do it cold or if its in neutral.

 

My 2005 is in the shop for the same thing. Couldn't find anything loose -heat shields etc...

Finally they found that the 'guts' of one of the cats was broken loose. Waiting on a new cat now.

 

Keep us posted. Very interested to find out if a new cat will solve the rattle...

 

ba,

so it wasn't the plastic intake tube? sounds just like a problem i had. check the "Rattling noise from engine area " thread if interested in my resolution.

 

yeah, did you check your stock intake tube? (assuming you still have a stock intake).

back when I still had a stock intake, it barely came loose from the end where it sticks into the fenderwell. I was getting a rattling sound under the same scenario you indicated. I fixed/reseated the intake tube in the fenderwell hole and no more rattling sounds after that.

 

When I read your original post, I was very hopeful that my problem was the same as yours (intake tube). Anyway, I thoroughly check it out, removed & reinstalled (even added foam padding), but to no avail. The noise is still there, and I'm confident it's not the intake...

 

I took my truck in about 5 times before they figured out my intake tube was loose. They then tightened it up and no noise ever since. This will save you alot of time and heart ache.

 

Ok, then maybe I need to re-visit the intake tube. What exactly did they 'tighten up'? The bolt half-way down the tube that secures it?

I completely removed the entire intake tube from the filter to the fender well. I reinstalled everything, making sure everything was nice 'n tight. I even added some foam padding between the tube and the mounting bracket where it bolts down.

What else can I do to ensure it isn't the intake? Is there something I could of missed? Another thing that leads me to think it's NOT the intake is that there was no difference in the rattle after I re-installed the intake; it sounded exactly the same...

 

If your truck is 4X4 then have them check the vacuum lines that keep it engaged or disengaged. I had a similar problem and it turned out one of the vacuum lines was not sealed properly so the hubs where not completely disengaging.

Hope that helps.

 

Ok, so I feel like a fool... All those people told me to check the air intake, and I kept saying that I did check it (I actually removed & reinstalled it)... Anyway, last night I decided to take another stab at the intake tube. I completely removed, just as I had before, but this time I noticed that the rubber grommet/seal that is on the end of the tube where it enters the fender, it was rotated about 180 degrees from where it should be. The notch was on the opposite side. So I rotated it, and reinstalled it, and... no noise so far!!!

So it looks like the problem was, not that the rubber seal was missing, but that it was improperly installed. Hopefully it will remain quiet, so I can enjoy the nice quiet ride

Thank to all for your help... And go ahead, say it, "I told you so"...

 

New cat -no more rattle!

 

Does your truck have the turbos I just had mine in the shop today was told it’s the turbo issue

 

No, this is a 16 year old thread from long before the Ecoboost. Please start a new thread in the correct forum section with YOUR truck details and a full description of your issue if you want help. Thank you!

 

I'm trying to figure out if you ever solved this noise. I have EXACTLY the same situation. It sounds almost like an exhaust leak, but it's coming from the air intake area in the engine compartment. Always around 1000 RPM. I can totally duplicate the problem. No idea. Wondering if a bad IAC gasket could do this.