2003 F250 mystery rattle
Hi guys, new to this site and am coming here since my dealership is pretty much worthless with troubleshooting a problem I have.
I have '03 F250 super duty with the V10. For about the last 15 months I've had a mystery rattle that occured only during acceleration and only at 25 and 35 mph. The noise is a tinny sound almost like a loose heat shield. I've had it in to the dealership 10 times and they've tightened every heat shield they could find with no luck clearing the rattle. They said I had a crack in the weld of my exhaust so I took it in to my exhaust guy who patched the weld and it didn't fix the noise. Next they said it was my catalytic converter and they replaced it and now the noise is louder, has changed pitch, and occurs more frequently, now including 15 mph along with 25 and 35 mph (still only during acceleration). Now the dealership wants to tear into my transmission saying they now think it's the torque converter. I think they're just guessing at this point. I have no issues with shifting or sluggishness at all when my truck shifts gears, and since the noise occurs more often since they changed out the cat I'm of the belief the rattle may still be associated with my exhaust.
The noise is coming from somewhere near the front of the vehicle, but since I hear it when I'm driving it's difficult to narrow it down. There is no vibration associated with the noise. The rattle is loud enough that when I drive through a neighborhood the noise reverberates off the houses and people actually stop and look at me when they hear the sound.
Do any of you guys have any ideas or guesses as to what may be rattling? Thanks so much!