Hey Guys,
I have a 2006 FX4 Supercrew with an edge programmer and a afe cai. I have just under 30,000 miles on it. Yesterday i started the truck with my remote starter and when i got outside to the truck i noticed a loud rattle noise coming from under the truck. I know the noise wasnt there the day before when i made a six hour drive home from work but now its there and not going away. Its a rattle noise, it almost sounds like some rocks rolling around in there somewhere. The noise is not very noticeable from the front of the truck, even with the hood open. but its quite loud coming from either side coming from under the truck. I can't get it into the dealership for over a week so i was wondering if anyone had experenced something like this before so i can understand how serious of a problem it is.
Thanks for any help you guys can offer...

 

Crawl under and check your exhaust heat shields. That's the easiest thing to check.

 

Six hour drive to work? Are ya sure it's the truck that's rattlin'??

 

If it's not the shields then:

- check all exhaust hangers

- internal baffle separation in muffler

 

Everything mentioned above is correct - you got the good guys helping you out on this one

You have a later model, but I think there purdy much the same as the older ones as far as the heat shields.

The common raddle point is in drive with the brakes engaged - Like going thru the "Micky D's" drive thru is when the rattle is at it's worst.

FORD MOTOR is aware of this problem , therefore has produced a TSB for the fix.

From the TSB -



Good Luck

 

Thanks for all the info guys.

So I got under there to check it out.. I can't seem to find anything that is loose that would cause the noise. But i started the truck and got under and the noise is for sure coming from the catalytic converters. It sounds like there is a rock or ball bearing or something inside flying around rattling against the sides. Its louder on the drivers side one but i can hear it in both. Could just be the sound from one echo into the other, not sure. Anyone experienced this before? Didnt think I would be having problems at this low mileage. The truck still drives fine, there is no ruff idle or lost power. Do you think it would cause any damage to be driving the truck until i can get it into my dealership?

 

I wouldn't think so - this sounds like the catalyst inside has cracked, ( it's really brittle), and is just bouncing around in there. Potential problem would be fragments going downstream and dropping into the muffler ( 06 - only 2 cats) and rattling in there too.

Warranty replacement of the cat - asap. And perhaps dump any crap outta the muffler.

 

You won't feel anything loose when cold - it's when they heat up they loosen - get the clamps and wrap just one around both sides - you should notice a difference .

If that doesn't work (i think it will) then you cats are compromised from the insides - there shot..

If there under warrenty - hell yes, take her in - no you won't hurt it.

 

I was just going to say faulty Catalytic converters, I had a Crown Vic, that sounds like what your saying, it was bad converters, warrantee deal on that one................go underneath vehicle, & strike the cats, if they rattle like something is loose inside, that is it...............