I went to the local dealership to get what I thought was a exhaust leak looked at on my 2002 F150 Harley Davidson. They confirmed that it sounded like a fluttering noise coming from the catalytic converter on the drivers side. They ran a oasis report on my vin # for 403000- Exhaust system concerns. They came up with special service message #16751 stating " 1997-2003 F150 and 1997-1998 F250LD may exhibit a noise coming from the catalytic converter shell that sounds similsr to loose internal components. If normal workshop manual diagnostic procedures do not indicate an exhaust system malfunction, the catalyst should not be replaced. Ford engineering is working on a repair procedure which should be released in the near future. Please monitor oasis for updates." So then they proceeded to let me know to check back with them at my next oil change, and they hope it doesn't get too bad. So now I get to drive around my brand new truck ( it has 7000 miles on it ) with an exhaust leak sound bouncing off every wall and chevy that I pass! I feel like I have been SCR@W@D! Please let me know if you have any advice that I can take to a different dealership with me. The one where I bought the truck is too far, and I don't think the service manager likes me anymore. Plenty of good dealerships in the Denver area to develop good relations with.
Scott

 

Just wondering if anyone knows more info about this problem. I have it on my 03 SCrew.

 

ok theres 2 ways to fix this if its what i think it is

the cat has a heat sheild on it. inbetween the sheild and cat there is a tag welded on to the cat these rattle sometime i usually just dig the tag out with a screw driver.

the other thing is one or more of the welds on the sheild broke these are fixed with a simple long hose clamp that will wrap around the cat heat sheild and pull it tight to the cat getting rid of vibration. sometimes requires 2 hose clamps

 

I am also hoping for a solution to this "exhaust leak noise".
My 01 screw sounds like a vega when i accelerate.
The dealer refused to do anything about it three times and stated that this was normal catalytic converter noise. Listening to them at idle you cannot hear the noise except through a stethoscope. That makes it very loud.
I finally ordered two magnaflow replacement cats from Troyer and talked a mechanic into taking off the two that were loudest and replacing them. This helped somewhat but the pre-cats also seem to make this noise. I am hesitant to just cut them out as I am concerned with long term problems of resale or emissions tests despite assurances that the magnaflows are sufficient without the pre-cats. I am also concerned that this may not be the real problem since it sounds so much like a leak. Three muffler companies have stated that there is no leak. Ford waranty people just say take it back to the dealer. They act like I am crazy. Now that I have messed with the other two cats, I doubt they will even talk to me.
I have a guy who will cut them off but, again, it worries me to do that.
Any advice would be appreciated.