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Ok, I have taken off the bug shield as of this morning and took the truck out for a test drive. Walla, wind noise was greatly reduced, and the hood and wipers no longer rattle.
It's still going to the dealer this week for wind noise and the "Transmission Fault" message, so I will post back with results. I will most likely re-install the bug shield after I get it back just to see what happens.
My XLT SCrew was built 10/23/03 in Kansas. 5.4L 3.55 LS. Truck has been at the dealer since Thursday 4/15/04. Truck is getting the clutch pack (had an almost indecernable "humming" sound at 70+mph with neutral throttle input and a slight shudder on left turn when truck is cold), PCM flash, and the dealer has spent more than a day trying to figure out what is causing the wind-noise. Sounds like its coming from the center of the windshield (above 40mph). Service people drove other F-150's on the lot and said that mine is definitly much louder. Funny thing is the wind noise has gotten worse since I purchased the truck. It has 1350 miles on it now, and I find myself having to talk over the noise. Hopefully they will get it squared away. I love my truck!
BTW - loaner Chevy Colorado crew cab is a POS, but very fast!
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