Rattle

[04ebexpy]

I have a rattle it sounds like coming from mid or rear only on light gas between about 1200-2000. no codes doesnt seem to have any misfires. attempted to locate the noise through replication while parked and could not get the expedition to do it. seems only under load. anyone have a similar issue or seen similar?

2004 expedition eddie bauer 4.6

 

[1955moose]

4.6 is famous for clogged egr passage. It's possible its not allowing Egr to flow. That could possibly be causing it. I'd check to be sure everything's clear, and flowing. Also run codes through data port. Report back your findings.

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[johnboneske]

I have a rattle it sounds like coming from mid or rear only on light gas between about 1200-2000. no codes doesnt seem to have any misfires. attempted to locate the noise through replication while parked and could not get the expedition to do it. seems only under load. anyone have a similar issue or seen similar?

2004 expedition eddie bauer 4.6

Its possible one of the honeycombs are loose in one of the Cats... I had a very similar problem, after a few months the honeycomb turned inside it, then I had to have it replaced.

 

[04ebexpy]

The codes are clear I ran and cleared them after new coils and plugs all it had was a cylinder 6 miss that was resolved no codes since.

I will check the EGR.

The sound only happens in drive both park and neutral I can rev the expedition repeatedly with no issue. Only in drive do I have an issue and only specifically from about 1200-2000 immediately stops outside that range.

 

[Ed_Strong]

I would start by jacking up the truck and supporting it with jackstands. Then crawling underneath the truck with a rubber mallet and start tapping on the exhaust system from the front cats towards the rear of the vehicle and see if you can replicate the rattle. Then do the same process with the chassis and underbody.

You can also take the opportunity to inspect the heatshields, suspension components and tranny mounts for any signs of wear and or looseness.

Where in Florida are you located?

 

[04ebexpy]

Pasco County. Sounds like a good plan once I have some time. I think honestly the most frustrating part and the reason I wasn't quick to blame the exhaust is the weirdness of how specific the conditions for the rattle are.

 

[1955moose]

Sounds like drive train. Anytime a vibration shows up only in gear you've narrowed it to transmission, driveshaft, anything that's engaging in gear. In park, only the motor is in play. Keep in touch.

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[Habbibie]

Sounds like drive train. Anytime a vibration shows up only in gear you've narrowed it to transmission, driveshaft, anything that's engaging in gear. In park, only the motor is in play. Keep in touch.

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That^^

 

[04ebexpy]

That's what I figured and I was afraid of with 202k who knows. I was hoping because it was so specific someone would chime in with an answer and let me be lazy but no such luck

 

[1997SCEBFEX]

all good advice above and hopefully you can find and resolve.
look forward to hearing what it was.

 

[04ebexpy]

Yea I plan to report back when I have the time to troubleshoot.

 

[1955moose]

It would be nice if symptoms are all the same part replacement, but these vehicles can be 2 or 3 different things for the same basic hurt. Thank goodness are body's are a little more predictable, or doctors would really have a time keeping us up and walking.

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[04ebexpy]

Was finally able to work on it today. Didn't find any heat shields loose. All my hangers for the exhaust are intact everything seems where it needs to be and tight.

The only think I can think of is the muffler looks like it may have a dent in it and my differential where the driveshaft enters is leaking slightly but there is fluid in the diff I checked.

Just to reiterate the noise is most often around 2200 rpms in gear and only while giving it has never coasting.

The area I consistently seem to pinpoint the noise to is the drivers rear somewhere between just in front of the third row and the tail gate.

At least I believe that's where it is.

 

[04ebexpy]

Bought a turbo muffler for cheap online I'm just going to cut the exhaust prior to the muffler and add that to elimate the muffler as my issue. Then I'd be stumped. Hopefully I get better mileage at that point because 10.5-11.5 kinda sucks.

 

[04ebexpy]

I read it could be one of my cats maybe? No sulfur smell but did get a p0420 code the other day out of nowhere. Hasn't come back since I cleared it though. Any other signs maybe as far as gas mileage I get 12.5 calculated on the dash if I really try.

Last question if it was a cat heatshield would you hear it all the way near the back?

 

[1955moose]

Noises are sometimes the most difficult to pinpoint. Rather than throwing parts like muffler or cat is not the way to go about. What about have a shop do one of their free or low cost inspections first. Some of your better shops have the Snap on audio ears, that can be mounted in different spots under vehicle, to help pinpoint the noise. Don't be like some past member's that replaced half the vehicle, just to find out it was a$2.00 part broken, or loose!

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[04ebexpy]

Put some cheap tires on the expedition and had the shop take a look see for my rattle they agreed with me that something is broken loose in the muffler so exhaust mods are imminent nothing special just a turbo muffler dumping under the body.

New projects found though as I thought my suspension is solid with the exception of one outer tie rod that’s just barely starting to go bad so I have that coming in so I can align it.

Next mystery is my TPMS fault and why only get about 300 miles from an entire tank of shell gas.

 

[04ebexpy]

Cut out the muffler and either it’s fixed or it’s so loud I can’t hear it unfortunately the dang hangers are in the way so I can’t put my new muffler on so the solution is in the planning stage while I run around straight piped.

I think the solution may be similar to the walker 41726 I just have to figure out how big the donut and incoming diameter is on the exhaust flange to the y pipe it would be super annoying to buy the wrong one

Side note as soon as I cut the muffler off and drove the mpg on the dash went from 11.6 to 12 so that was interesting and hopefully the change keeps up