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I had the exact same symptoms on my '03 4.6. It drove me %*$&% crazy. Ultimately the problem turned out to be the heat shield on catalytic converter. I had the cats replaced under warranty for a different reason and the rattle went away.

I had the same problem with my '03 Explorer. Add more refrigerant.

I went with the General Grabber HTS in March and have found them to be a great tire so far.

Check your A/C refrigerant level. I have the same system in my '03 limited and had the exact same problem. I went as far as replacing the driver's side actuator but still had the "warm driver, cold passenger, cold rear" symptom. The problem went away after I added another 12oz can of R134a.

I recently installed the PIE FRDN-AUX in my '03 Limited w/the 6 disk changer (815 series). In my vehicle there was an unused power connector under the center console that I used for power and ground. I Installed a Jensen Marine JPORT 1/8" audio jack in the center console instead of having to...

I turn mine off when I have my bike rack mounted as the rack blocks the sensors sets off the audio alert.

Hi Scott, You're going through exactly the same sequence of events and troubleshooting I went through. I went as far as replacing the driver's side actuator as I also experienced the wintertime clicking noise. However, I still had the same air conditioning experience (warm air driver side...

My '03 Ex does something similar. I've found if I pause on R for a second or two on my way to P there's no "bump". Not sure about the underlying root cause...

I replaced the front/driver's side blend door actuator on my 2003 Explorer Limited last week using the excellent info in this post. My Ex has DATC. I noticed a couple of differences between the excellent info posted here regarding the manual climate control and my vehicle's DATC...

Hey - Floatflyer! Do yourself a favor: check for the broken black ground wire. It's really not that difficult to get into the door and the wire bundle.

Hey everybody, I just resolved this issue on my 2003 Limited and thought I'd share my experience. When my vehicle first started displaying the "Door Ajar" message several years ago, the WD-40 solution would resolve the problem for many months. However, about six months ago the problem...

Had my catalytic converter replaced today and my rattle is gone.

A quick update for those who may find themselves at this thread. I had my catalytic converter replaced today, and my mysterious rattle is gone. I'm no expert on the exhaust system, but I'm guessing a shield or exhaust component was responsible for my rattle.

I stumbled upon this document while looking for information on torque converters. It contains excellent photos of all the parts in the 5R55W tranny, plus other useful information. http://www.ratiotek.com/5r55w-complete.pdf

Are you satisfied with these bearings? Did they come with new ABS sensors and hub bolts?

Did you ever discover the source of your noise? My '03 is making a similar sound under similar conditions (rpm range; only when in gear, etc).

I had the same problem about 10k mikes ago. The WD40 method worked like a charm for me.

Excellent! I have the same radio and hit the same roadblock a couple of years ago when I picked up a similar style of satellite radio.

Did you ever figure out your rattle? My '03 Limited has a noise in a similar RPM range.