Rattle Under Boost

[LeadFootLarry]

Maybe someone here can help me more...please lol. Half a dozen visits to dealers and local mechanics and not one can find the cause of this noise, with some not being able to reproduce it and brushing me off. This video is from the outside this morning on a cold start, it rarely if ever makes the noise when cold. Loud metallic rattle from underneath truck under certain engine loads, typically in high gear, low RPM when engine warmed up. Anyone ever heard something similar?

 

[FordTechOne]

Maybe someone here can help me more...please lol. Half a dozen visits to dealers and local mechanics and not one can find the cause of this noise, with some not being able to reproduce it and brushing me off. This video is from the outside this morning on a cold start, it rarely if ever makes the noise when cold. Loud metallic rattle from underneath truck under certain engine loads, typically in high gear, low RPM when engine warmed up. Anyone ever heard something similar?

Do you have an aftermarket exhaust? Yours seems louder than mine but maybe it’s just the video. Since the noise occurs at idle with the truck stationary, it’s definitely not IWE related. Can you determine the area it’s originating from or does it sound the same regardless of where you listen from?

 

[KAJRIP]

Maybe someone here can help me more...please lol. Half a dozen visits to dealers and local mechanics and not one can find the cause of this noise, with some not being able to reproduce it and brushing me off. This video is from the outside this morning on a cold start, it rarely if ever makes the noise when cold. Loud metallic rattle from underneath truck under certain engine loads, typically in high gear, low RPM when engine warmed up. Anyone ever heard something similar?

Maybe coming from the HPFP (fuel pump) in/on the passenger side valve cover. They make quite a bit of noise at times. Try taking the foam engine cover off to hear it better maybe.

 

[LeadFootLarry]

Hi @FordTechOne, yes I do have a Corsa Sport Catback. I have had 2 different shops check the exhaust for loose clamps, hangars, etc. and both have found nothing of suspicion and said that it’s installed well. I should note that the rattle follows RPM’s, meaning if the RPM’s increase, the rattle follows and gets faster and a bit louder. Banging on the exhaust with a rubber mallet also yields no noises.

The noise itself seems to be located more towards the middle of the vehicle, and doesn’t sound too much different if I move towards the rear.

 

[TwizzleStix]

Maybe someone here can help me more...please lol. Half a dozen visits to dealers and local mechanics and not one can find the cause of this noise, with some not being able to reproduce it and brushing me off. This video is from the outside this morning on a cold start, it rarely if ever makes the noise when cold. Loud metallic rattle from underneath truck under certain engine loads, typically in high gear, low RPM when engine warmed up. Anyone ever heard something similar?...

The noise in the vid is wastegate rattles. They rattle both hot and cold, depending on what you're doing.

 

[TwizzleStix]

You can buy a kit that comes with 4 wireless microphones (channels for 6) you can place in specific areas to hear the noises while driving. It's called the Steelman Wireless ChassisEar. It's not real expensive, but I forget how much it was. Never pay anyone to find noises because they won't, unless they use something like this kit. The dealer goons don't make money while diagnosing noises, they get paid to replace parts, so they won't put any real effort into finding a noise, especially for warranty work. See attached pic.

 

[LeadFootLarry]

Thank you for that @TwizzleStix

 

[FordTechOne]

Hi @FordTechOne, yes I do have a Corsa Sport Catback. I have had 2 different shops check the exhaust for loose clamps, hangars, etc. and both have found nothing of suspicion and said that it’s installed well. I should note that the rattle follows RPM’s, meaning if the RPM’s increase, the rattle follows and gets faster and a bit louder. Banging on the exhaust with a rubber mallet also yields no noises.

The noise itself seems to be located more towards the middle of the vehicle, and doesn’t sound too much different if I move towards the rear.

What you may be hearing is normal engine noise (such as wastegate rattle as @TwizzleStix mentioned) being amplified through the exhaust. This can happen as newly installed components, such as an exhaust, settle in. To eliminate that possibility, you can perform what is called an exhaust neutralization procedure. It involves loosening all individual connections to allow the exhaust to settle, and then retorquing all connections per the manufacturer’s instructions. Might be worth a try.

 

[LeadFootLarry]

Thank you all for the suggestions and ideas, I’ll start with the neutralization procedure tomorrow and work from there

 

[dweb27]

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

So did you ever get a fix for this? I have a 2019 F-150, been in the shop 5x's for this, the last one after a 4x4 fail where the dash flashed "4x4 Temporarily Disabled". Had grinding in the left front hub area when it failed. Clearly the IWE/Actuator or something in the hub isn't right. Fords final suggestion was to "cap-off" the vacuum system, permanently locking in the IWE assembly with full-time spinning of the front axles -- which just doesn't seem right..