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Exhaust hanger? Loose manifold flange? Fuel or transmission lines?
No, no, and no. Completely new exhaust system and headers. Everything is tight. Fuel and transmission lines are tight. The sound is like a sheet metal rattle.
Originally Posted by blue 80
How many miles does the engine have? the timing chain idea is pretty much my thoughts.
About 3000 miles on the rebuilt 302 engine and rebuilt AOD transmission. Timing chain, cam, and lifters were replaced with Comp Cams 31-255-5 and matching components when the engine was rebuilt.
The rattle isn't heard while driving or under load.
I had an 88 F150 for a while giving the symptoms you've described.
At first I'd thought the rattle was in the exhaust but the more I listened, it sounded like it was coming from the rear of the oil pan or torque converter area.
So I took it to a transmission rebuilder, in case a vane had broken loose in the converter (I was planning on selling it & didn't want it to give the new owner trouble).
He listened & hunted for a while with a stethoscope & finally said he thought it was the exhaust too.
It had two catalytic converters, one was next to the trans bellhousing.
I cut open the converter & the the noise had been caused by the honeycomb material (can't remember the proper name) breaking up - at an idle pieces would rattle around but at higher rpm there was no noise.
Tore it all out & welded the exhaust closed again - SILENCE!
PS Just saw you had a new exhaust, so probably this is NO help
one more time have you used a stethascope on it yet and listen at various areas of engine when you are near problem you will hear it just be carefull and dont place tip in fan will scare sheet outta ya and dont ask how i know this. But seriously get a stethascope best way to find strange noises.
YES, I held a vacuum hose to my ear attached to a socket extension and I heard all sorts of cool sounds. No rattle or knocking sounds are coming from the top of the motor. Its definitely at the bottom of the motor.
The sound is coming from around the back of the oil pan, around the starter, and around the transmission where it bolts to the engine.
Is the starter drive not pulling back far enough? Had kinda the same issue you describe when i put a new starter drive in my 68 250 w/390. The return spring few out and i didn't even notice (it had been a long day). Took the starter back off and found the drive didn't retract and it kept skipping on the flywheel teeth, at higher rpms i think there was enough wind in there to push the drive away but at idle it would start up again.
If you can shine a light up through the inspection cover and look for any contact. And id pull the starter and see if the drive is loose in there. You can take the top cover off the starter and check the movement by working the arm. If its a reman check the part number and make sure its the right one, ford has different tooth counts and nose profiles and the like
I doubt this will solve your problem but grease the fittings on the steering in front. There are 4 grease fittings on the 84 I have. I had a good vibration until I did this. After it went away. No problems since.
I just had a good friend check it out, who owns his own transmission shop. He did find the starter was binding up some, and he rebuilt it for me. He inspected everything else, including the flex plate and replaced the torque converter.
The rattle is still there!
Using a screwdriver as a stethoscope, he told me that the noise is coming from the front of the engine, but he is stumped too. He doesn't think it is a rod or bearing noise.
Then the only other thing i can think of is what franklin said in post #11, concernig the timing chain slapping the cover, check that with a long screwdriver and see if the noise is louder
I've been watching this thread hoping you find a culprit to your problem. When the timing chain was mentioned earlier it was something the didnt occur to me, and it sounds like you've looked everywhere else. Pull the belts off completely and fire up the engine, put a stetho on the timing cover and see how it sounds.
I have a strange rattle or knock on my truck as well. It's not there at idle, but just above idle for maybe the first 200 rpms past idle. My first thought was something internal, like a rod or main, which I'm not ruling out, but I've been watching this thread so that when I finally take the time to investigate the noise, I'll cover all the suggestions mentioned here. I'm a pretty good mechanic, did it professionally for many years, and if I can't figure something out and it's giving me a fit, it always turns out to be something so simple that I overlooked or didn't consider. Doh!
Have you checked the dust shield on the rear axle yoke? Mine is rattling right now because it is loose. They are pressed onto the yoke and sometimes loose their interference fit when they are hit by road debris or rust and start spinning on the yoke. Just a suggestion.
OK, I found a certified mechanic to put it up on a lift for me and he checked everything out with a stethoscope. He narrowed it down to the area around the fuel pump. Even though the old fuel pump looked fine, I replaced the fuel pump, and the noise went away.
When the truck is warmed up, the rattle comes back. If I let the engine cool, the noise is gone until it warms back up, and then the noise returns.
Could it be the eccentric on the end of the cam? But keep in mind the pump mounts in the timing cover also, still could be that chain but IIRC the eccentric can be damaged by putting te pump in wrong. Id pop the timing cover off and take a look