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I just bought a 2002 f250 with a 5.4L and a 4r100 tranny. It has 87,000mi on it.
There is a rattle in the transmission when it shifts from D to OD. the sound is the same as when a hydraulic lifter sticks and rattles. the noise only lasts for the first half of the shift. It also only does it after the transmission is warm(about 30-40mi.)
Has this happened to anyone else Please help, I don't want to fix the wrong problem.
Are ya' sure it's from the tranny? I had a similar problem on an old buick I once owned. Turned out that the heat shield on the converter had a busted weld. When the engine was at the shift point, the load on it would change and it would evidently cause the exhaust to vibrate momentarilly and thus make the heat sheild rattle. Strange but true.....
Does it do it at about 45 mph? You may want to look at the torque converter. I have this problem, it sounds as if you ran over the rumble strips on the side of the highway. I have the same truck as you.
I tried the rattling exhaust idea, checked everywhere I could see and fixed a couple of spots that might have rubbed but the noise is still there. There is a slight vibration in the truck at about 45mph, but the noise seems to happen more around 55-65. And it is not near as loud as rumble strips, it is very quiet. If anyone has more ideas they would be appreciated. I have a friend that will look at it Sunday, I'll let you know if he can figure it out.