There is a metallic rattling noise coming from the front right end. The noise has gotten progressively worse the past few months and its driving me nuts. It sounds like its coming from the wheel but I am not totally sure. Its hard to listen to a noise with your head out the window at speed . We looked under the truck and hit everything we could with a rubber mallet to re-create the noise. We pulled the right front wheel off and we thought it may have been the brake rotor shield but no dice. The bolts holding the shock were slightly loose but we tightened them but the noise was still there. The noise has the characteristics of a wheel bearing, but there is no slop and the wheel doesn't make the noise while in the air. It starts to make noise 20mph and up while accelerating. While cruising there is rarely any noise but if I come up to a slight grade it starts to make noise a little. 1500rpm and up is when it typically makes it. If it makes the noise and I let off just a little it quits.

Truck is an 04 150 with the 5.4.

I hope that made sense.

Help would be greatly appreciated.

 

check out the heat shielding for the exhaust for fun, that thing rattled on my truck and drove me nuts til one of the bolts fell out, now its hanging outta the way barely.

wheel bearing for me made a hell of a racket, but it wasnt a rattling noise. rather it was a grind.

 

Have you checked the brake caliper bolts and anti-rattle hardware for the pads yet?

 

muffler clamp

 

All the heat shields are out the way and are fairly secure. I ruled out wheel bearing because the noise doesn't increase while going around corners. Caliper bolts and braking components are tight and exhaust system is tight. The noise sounds like someone is shooting a high rate of fire bb gun (with small dia. bb's) at a thin metal part. Thats the best way I can describe it. I searched the forums, and did what others said fixed the problem, but noise is still present.

 

I had that rattlin noise on my '02-150. This noise drove me Fargin crazy. I chased the noise down to tiny gravel that had worked their way down inside the heat shields of the catalytic converter. I peeled back the heat shields just enough to get a piece of wire in there to fish out the pebbles. now no more rattle trap!
When the truck is cold, go and tap on the heat shields of the catalytic converter. I used the end of a big **** screwdriver. listen for that metalic sound then!

 

aint had cats in so long...

 

I just got done beating the hell out of my CC with a screwdriver. I really couldn't hear anything rattling. I took 120psi of air and blew it up in there and I had about 15 pebbles come out. Most of them being fairly small (think pencil tip) I am having my doubts that my problem has been resolved but I am still optimistic. I will know tomorrow on my drive to work weather or not the noise has decreased or stayed the same. I am going to call my Ford dealer tomorrow to see if they can scope my front cv's to hear if maybe that is my problem. I will keep you updated.

Chris

 

cv's make more of a thump sound?

 

My rattle noise was the pipe clamp at the crossover. Looked good but is was completly off rusted at the hanger. I originally thought it was the cat heat shield.

 

Good call, I will check into that!

 

Is it a 4x4 mine had the same problem and I found the prob

 

Yep, its a 4x4. Do tell on the solution, I am all ears!

 

twice i had an issue with the vac valve that locks the front hubs.It would leak which allowed some vacume to go to the hub.It would barely pull in which cause the gears to touch each other but not enought to lock in.The valve is on the passenger fire wall behind the battery.If you have an 04 as I do the valves did'nt have rain caps that thet do now.The rain pours off the windshield,down the cowl,and just guess where it drains,Ontop of the 4x4 valves.I'll try to send a pic of a rain shield I made to cover mine.Hope this helps.Also my truck would never make any funny sounds when it was in 4 wheel.Because the hubs were fully locked

 

I will try in 4wd. I never thought of checking into that, I will get back with you later on because that is a really good suggestion!