A4wd issues....maybe

[2k3Expy]

My Expedition started making this rattling sound about a week or so ago. It seems to be getting worse but looking for loose heat shields has turned up nothing. I was looking on here for ideas and I am thinking it could be a failing vacuum solenoid for the hubs. I recorded a vid with my phone and the rattle is pretty apparent on the video.

The truck shifts fine, A4wd works, 4wd H works, trans fluid does not smell and looks like it should.

Rattle 2003 Ford Expedition - YouTube

 

[2k3Expy]

Definitely not the hubs. Not sure what the hell it is but it is in the exhaust.

 

[Captain Morgan]

I watched your video and thought "exhaust manifold \ pipe" then saw your second post.

Can you lay under it and shake the junction where the manifolds meet? (this is where crap falls directly into your eyeballs)


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[2k3Expy]

It appears to be the worst at about 800-900 RPM. About 2 weeks ago I banged on it with a rubber mallet and the sound changed a bit. It appears to maybe be stuck in the front cat on the drivers side. What really disturbs me the most is that my truck runs great.

 

[FordandPolaris]

Could have broken catalyst inside of the cat. Might have to remove it to see whats up.

 

[2k3Expy]

Could have broken catalyst inside of the cat. Might have to remove it to see whats up.

Spent an hour yesterday feeling and banging on the cats. I would have to agree that something is just broken and rattling around in there.

Thanks for the help guys!