Knocking sound from lower engine
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Cross-Country
Joined: Mar 2019
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My 03 has had that same noise for 60,000 miles. It is really noticeable thru the wheel well behind the tire. It comes from the first small cat. There was actually a kit Ford sold that was used to wrap that cat. to deaden the sound. Unloaded idle it really gets knocking, put it in gear and it almost goes away. I was told it is harmonics between the cat and piston slap. Lot of 5.4 motors have that knock and it's NOT a phaser if it's an 03 or older. May or may not be your issue but worth bringing up.
Laughing Gas
Joined: Jan 2006
Posts: 1,098
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From: Minnesota
You're welcome. let us know what you find. I actually used a old stethoscope and checked the whole area and when I got to the front CAT....man it was really banging in my ear. Please be careful....things are very hot and RUNNING.
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Cross-Country
Joined: Mar 2019
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just got told my my buddy who is a mechanic that it’s cylinder 2 connecting rod
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Cross-Country
Joined: Mar 2019
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no, this person has done a lot of work regarding the rods, pistons, and bearing on these 2v and the 3v. As soon as he heard it, he said there wasn’t a doubt in his mind
New User
Joined: Dec 2020
Posts: 2
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Mine just started making a knocking sound coming from where you described. Also have a misfire coming from cylinder 4 I’m assuming it’s a manifold leak since the coil was covered in coolant. It’s a type a misfire (check engine light flashes) which can cause damage to the cat and the knocking started after I drove 180 miles with the misfire. So after reading on this thread about the knocking possibly coming from the cat I would say that it makes a lot of sense...
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