Rattle Under Boost

[KAJRIP]

@KAJRIP do you have a location on where the sound comes from? Mine seems to originate from the front passenger side of the vehicle

Yes. Same here.

 

[LeadFootLarry]

Guess we’ll see what the dealer says Wednesday. I’ll report back with any info

 

[LeadFootLarry]

So...update on this. Brough the truck in for the camera recall, they work fine now and even look more clear on my SYNC screen. About the rattle. I had that dealer check the rattle noise out and they said to me it’s normal turbocharger noise, referred me to a GSB for turbo noises. This noise is not normal, and I’m no mechanic...it’s louder in the cab, can’t imagine how it sounds outside lol.

So, later that day my OCD/paranoia kicked in and I called another nearby dealer after seeing a TSB referencing IWE noise that can be confused as turbo noise (TSB SSM 49355). This TSB gave me a hunch I was just misdiagnosed at the first dealership. Next day I drop my truck off at the other dealer, they had it for the day and said they couldn’t reproduce noise, etc etc. and I was losing hope..Finally get a call from the advisor stating that coincidentally during a test, the 4wd was trying to engage at speed while in 2H, thus allegedly causing this noise. When they tried to communicate, reflash, and connect to the module that controls this, it wasn’t responding at all indicating it has failed. They’ve ordered a new one, which is on back order and has no ETA, but hopefully it fixes the issue! Lesson learned, go with your gut and get a second opinion

 

[KAJRIP]

So...update on this. Brough the truck in for the camera recall, they work fine now and even look more clear on my SYNC screen. About the rattle. I had that dealer check the rattle noise out and they said to me it’s normal turbocharger noise, referred me to a GSB for turbo noises. This noise is not normal, and I’m no mechanic...it’s louder in the cab, can’t imagine how it sounds outside lol.

So, later that day my OCD/paranoia kicked in and I called another nearby dealer after seeing a TSB referencing IWE noise that can be confused as turbo noise (TSB SSM 49355). This TSB gave me a hunch I was just misdiagnosed at the first dealership. Next day I drop my truck off at the other dealer, they had it for the day and said they couldn’t reproduce noise, etc etc. and I was losing hope..Finally get a call from the advisor stating that coincidentally during a test, the 4wd was trying to engage at speed while in 2H, thus allegedly causing this noise. When they tried to communicate, reflash, and connect to the module that controls this, it wasn’t responding at all indicating it has failed. They’ve ordered a new one, which is on back order and has no ETA, but hopefully it fixes the issue! Lesson learned, go with your gut and get a second opinion

I had mine in for the camera recall as well this week.
Also told them about the noise and even offered to take someone for a ride to show them. I was immediately told no because of COVID.

Of course when I picked the truck up they said they could not reproduce the noise then suggested to have a tech go for a ride with me next time I bring it in. It’s going back in a week or so for a seat cover repair.

I’m glad to hear you were persistent and hopefully on the right track to get yours fixed. I guess I’m more of a “drive it until something explodes” kind of guy. Lol.

Thanks for the update and please keep us posted once you have the repair done.

 

[LeadFootLarry]

Truck goes in tomorrow for the module replacement (part #KL3Z7E453A), hoping this fixes the issue. In the meantime, the dealer has told me they have “manually locked the front hubs” on the truck. This may go without saying, but I’d like to inquire with @FordTechOne whether or not I should remind them to manually unlock the hubs or if the new functioning module will do this by itself?

 

[FordTechOne]

Truck goes in tomorrow for the module replacement (part #KL3Z7E453A), hoping this fixes the issue. In the meantime, the dealer has told me they have “manually locked the front hubs” on the truck. This may go without saying, but I’d like to inquire with @FordTechOne whether or not I should remind them to manually unlock the hubs or if the new functioning module will do this by itself?

Sounds like they disconnected the vacuum line, which causes the hubs to go into the default (locked) position. The module (TCCM) is the least likely cause; it's not even a causal part in the TSB. Sounds like misdiagnosis, but we will see.

 

[LeadFootLarry]

Thank you for the reply, I will post back with updates tomorrow They said the TCCM is kaput, so sounds like it needs a new one regardless

 

[LeadFootLarry]

Well @FordTechOne was right! Seems to be (another) misdiagnoses! They replaced the TCCM, road test to verify that no noise is present...But, after I get the truck back, and am driving it home, it continues to happen! Again the noise can best be described as a louder rattle/grind present inside and outside the vehicle. It seems to only occur at operating temp, under acceleration, and typically under light load or boost. Is there anything else I can point them in the right direction towards? They were pretty adamant about it not being IWE related, but I didn’t see any paperwork saying they checked the actual parts, only that they did a vacuum test

 

[FordTechOne]

Well @FordTechOne was right! Seems to be (another) misdiagnoses! They replaced the TCCM, road test to verify that no noise is present...But, after I get the truck back, and am driving it home, it continues to happen! Again the noise can best be described as a louder rattle/grind present inside and outside the vehicle. It seems to only occur at operating temp, under acceleration, and typically under light load or boost. Is there anything else I can point them in the right direction towards? They were pretty adamant about it not being IWE related, but I didn’t see any paperwork saying they checked the actual parts, only that they did a vacuum test

If it only occurs in 2WD and not 4WD, it’s 99% IWE related. I don’t understand why these dealers can’t diagnose a simple vacuum operated system. What year is the truck?

 

[LeadFootLarry]

@FordTechOne the truck is a 2020. The noise occurs in 2H and 4A, haven’t tested in other 4WD modes..It’s going back to the dealer tomorrow for the 4th time for this issue, I suggested they open up a hotline for this, and I offered to take someone on a road test which they have agreed to. How does the old saying go, 4th time’s the charm?

The parameters and conditions in which the noise appears baffles me, more specifically the truck needing to be warmed up to normal temps. Also, it seems like it *may* typically start to occur when the vacuum reads anywhere from 0-3.0 inHG, to when it transitions to PSI under boost. I have taken a video showing what it sounds like from inside with windows up and air on which may make it more difficult to hear unfortunately. Starts at roughly :05 under light acceleration and goes until the end of the video. It’s the metallic sound you hear in the background, don’t be misled by my grocery bag! Lol. Maybe this will help