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My 02 F150 5.4 4x4 appears to be one of those "Some" vehicles that makes the diesel/knock noise from the cat conv area. My brothers 03 5.4 doesn't; my friend's 02 4.6 doesn't. Other than using Ford's $400 cat converter wrap, I'm wondering if changing the exhaust manifolds out possibly even to headers, might change the impulse. Maybe only trying a junk yard cat converter/pipe assy will get rid of the knock/ticking noise.
If the ceramic substrate is loose or broken, the exhaust pulses will move it in the case and you are apt to hear it.
A mechanic's stethoscope would verify the source of the noise.
Rezvani's Latest Post-Apocalyptic Monster Is a Ford F-150 Raptor Underneath
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