I have had a rattling noise in the left front of my vehicle for two weeks now. Truck was in last week and they replaced a four wheel drive sensor near the fire wall. The thought was that the four wheel drive wasnt disengaging. Well that wasnt it. Had to take it back today. The rattle sounded like it was exhaust, maybe a loose heat shield or something loose in the catylitic converter. The noise was intermitent when driving but constent when backing up. Turns out it is the four wheel drive hub. Service says they are a poor design and they tend to wear out quickly. I have had my truck two years and have 25,000 miles. I have had my truck in 4 wheel 3 times....and pretty much just for the sake of excercising it and making sure it still worked. Wonder what kind of shaped they would be in if i really used it?!
28 visits to service now in two years. Just thought id share my headache with others in hopes it will help someone. Oh and if your wondering sure i could cry lemon but i dont feel like losing the 5 grand in cool stuff i put into it. The free warrenty they gave me for my troubles will sufice for now. Who knows.

 

I've had my 04 Reg Cab F150 since Dec 03, have 34,700 on it and have used the 4x4 a LOT during the winter due to snow conditions. No noise or problems with it yet. MY rattle noise is in the rightside lower area of the doors. Sounds like a tick or metallic tap, listened to it with my stethoscope (while the wife drove of course!) confirmed that's the area it's coming from, much worse on warm to hot days than cooler days. Ford shop has had it ( 2 times) and took the door panels off and couldn't find anything. The same noise is now happening in the drivers side door occasionally. Wonder if I can do a Lemon Law claim because of this, I don't want to listen to this rattle for the next 70-80,000 miles. The noise just started last winter.