DAVID'S97F250HD

I thought about injectors, did you try disconnection them below valve cover one by one to see if the noise would go away.

I will be pulling the tranny out soon as I get a place or a reasonable labor quote. Will inspect/replace flexplate or TC.
Have you done it?

 

I did'nt dissconnect them idividually but in pairs outside of the valve cover, I had in issue of what sounded like a knock/cackle at idle, in neutral if I spiked the RPM's for a moment when the engine is accelerating under no load I noticed a audiable miss but otherwise drove fine. The cackle cleared up when I unplugged the pair of injectors and the miss which almost sounded like a "bark" in the exhaust(running straight pipe) went away. Changed the injector O-rings and thier was a very noticable improvment and the o-rings where for sure at fault.

Also before I did this if I would stall test the transmission the truck would shake, after this that was nearly eliminated. I had changed my flexplate because it exceded the run out allowable but no real improvment was found about that. Being that your truck has such low K's I would almost cast doubt on injector O-rings being the fault. Mine was doing this fault with no fuel in the oil but everytime it "barked" in the exhaust I would get a puff of blue smoke associated with it.

As for flexplate, you can pull the inspection cover off yourself, it is a little bit of a pain in the *** cause of the the bolts it unaccesable do to the starter. Start the truck up and see if the noise is louder and 2ndly look at the flywheel while running, you should see no movement of the flywheel toward the front and back of of the truck. with truck off you can clasp the torque converter and rock it left to right in proportion to the truck, if it moves, either the torque converter is loose or the flywheel is cracked. Could be cracked if it does'nt move left to right but moves forward and back while engine is running. I have seen these flywheels broken/cracked before.

I start work in 9 hours, I'll check the TSB's at work and let you know what I find about cackle if it was included for our years or not.

 

I found few TSBs that might be related.
I am 99% sure that my truck model is not California. But symptoms seems simular.

"Engine noise similar to a rod knock may be heard on some vehicles. This noise usually occurs at idle, but can occur at other speeds and is due to the combustion characteristics of the new injectors for California emission vehicles with a 7.3L DIT engine."

https://www.ford-trucks.com/tsb/full...p?tsb=03-21-13

Also
IDLE - ROUGH - POOR SEAL ON INJECTOR O-RINGS - 7.3L DI TURBO
https://www.ford-trucks.com/tsb/full...p?tsb=98-23-13

Also Flex Plate TSB
https://www.ford-trucks.com/tsb/full...hp?tsb=99-23-6

 

HEY, YEAH i JUST FINISHED CHECKing out the TSB's hear at work, thats what I was thinking when I was sure I remember seeing our year truck on the r4100 trans(ours being e4od). Thats what I was getting mixed up about.


As for the cackle, nothing but on 99's.............

check out that flexplate.

 

I did not quite understand, but I am sure 96 PSD had E4OD trannys in them.

Yea, time to check that flexplate.

 

thats where mine sits