Bluewind....thanks for the vid!

96BULLITTGT....thanks for the list. This vehicle was a trade in- service said the did the breaks and put 2 new tires on it before it went back out on the lot.

I've brought the vehicle to the Ford Dealer shop (for unrelated issues) and asked them to look at it. Both times they said they couldn't find anything loose when they put it up to look. The 2nd time, they said they drove it, but couldn't get the rattle to happen (its driving me nuts).

After I rotated the tires, it seemed to stop for a few days, then started up again when the wife hit a rough spot. I don't get it.

I know how you feel!

Tracking down a noise can be difficult.
Rotational noise: does it grow with the vehicle speed or with the engine RPMs? It would either be related to the hubs/brakes/wheels or the engine.
Suspension noise: occurs when hitting bumps: sway bar bushings, sway bar endlinks, struts, lower ball joints
Steering noise: inner tie rod ends, outer tie rod ends, ball joints, strut bearings.

This grouping may help you closing in on it. Jack up the car and put it on jack stands for your safety. Use a rubber mallet or wooden block and tap on everything under the vehicle you can get to. You hope to create a noise that is similar to the one you hear while you drive. This method is based on the theory that everything has its own frequency.

Good luck!

I replaced the coil pack on mine at 80k miles after it started acting up. It took me a few hours to remove all the wiper arms, cowl shield, plug wires, pack, etc and replace it all without screwing it up. When it fails it won't strand you, it just will start running rough, so I would agree with Bullitt on this one. Don't bother replacing it unless it starts acting up. On others advice, while I had it apart I made a plastic shield and siliconed over where the ECM is also to prevent moisture from getting in there.
As for the MPG, we have averaged from 12mpg to 25mpg, with overall around 18mpg. Check out Fuelly.com for user based MPG info on all vehicles.

I have 134,000 miles on my 04' and get basically the same as "mercury4ever gets. The MPG is going to depend on cargo, temperature, MPH, carting a big wind brick on the roof, tire size, who's driving and everything else in-between. I set the cruise 5 over the speed limit, the wife sets it for 5 over the speed limit and then steps on the gas:).