Loud Rattling Noise Upon Cold Engine Start

[peterk9]

It has to do with your variable valve timing actuator mine does it too it just recently started and I have a 2013 police interceptor utility..

Welcome to the Forum.

Peter

 

[Steverino951]

Nice work! Thank you for sharing. Does the passenger side not rattle?

Nope, but that side flex mesh covering vibrated itself apart. Nothing left of it now. Not sure what it was there for really. The drivers side now has a clamp on it with a exhaust hanger rubber to absorb the vibration. It has removed 95% of the sound during warmup. Totally gone while driving.

 

[themishmosh]

Just ordered the Lethal Performance mid pipes which are supposed to fit stock setups. It's probably more expensive than getting flex sections replaced locally but I would trust the build quality of the LP mid pipes so much more and it's something I can install.

Lethal Performance PLLP00005M 2.5" Stainless Steel Mid Pipes (2020-2025 Ford Explorer ST 3.0L)

The Lethal Performance 2.5" Stainless Steel Mid Pipes for the 2020+ Ford Explorer ST 3.0L are a direct replacement for your factory midpipes which require no cutting or welding for installation. These will replace the factory piping in between the downpipes and catback. These pipes are...

www.lethalperformance.com

 

[themishmosh]

Installed the lethal performance part I referenced earlier. Fits stock exhaust just fine. It was not fun due to rusty clamps after 3 years of ownership but I got it done. I did have to rent a tail pipe expander at AutoZone because it was hard to slip the new mid pipe into one of the stock ends. Also, I was looking for a rattle fix and ended up finding that one of the flex sections had failed anyways. It's no wonder I thought the exhaust sounded louder with throttle. Not sure if a new OE mid pipe would have been covered in the drive train warranty (I have 48k miles) but I've heard reports of the "improved" OE mid pipe having the same rattling and failure problem so didn't want the hassle.

 

[breddy]

Just ordered the Lethal Performance mid pipes which are supposed to fit stock setups. It's probably more expensive than getting flex sections replaced locally but I would trust the build quality of the LP mid pipes so much more and it's something I can install.

Lethal Performance PLLP00005M 2.5" Stainless Steel Mid Pipes (2020-2025 Ford Explorer ST 3.0L)

The Lethal Performance 2.5" Stainless Steel Mid Pipes for the 2020+ Ford Explorer ST 3.0L are a direct replacement for your factory midpipes which require no cutting or welding for installation. These will replace the factory piping in between the downpipes and catback. These pipes are...

www.lethalperformance.com

This issue has cropped up on our 2020 ST. The TSB clamp solution fixed it for some time but it's back. Dealer said it's the flex pipe and what he described is exactly like what's in this video:



We're out of factory warranty and the parts are over $700. Fidelity won't cover it (exhaust excluded). My question is what is the benefit of the LP mid pipe other than to just replace the Ford one? There's no resonator delete or anything, right? The LP one is $450 or so which is more palatable than the factory's 750 or so. I'm guessing a local muffler shop could put it on in an hour.

edit: I guess stainless vs aluminized is the benefit?

 

[Jamestex]

Hi, our 2020 Explorer ST is currently in the shop due to a loud rattling noise when the cold engine is started. This did not occur when the vehicle was new but I was just notified by the dealership that this would be 'normal'. Does your vehicle make this sound, too?

Rattling Sound

Thanks in advance!

Check ur timing chain

 

[themishmosh]

We're out of factory warranty and the parts are over $700. Fidelity won't cover it (exhaust excluded). My question is what is the benefit of the LP mid pipe other than to just replace the Ford one? There's no resonator delete or anything, right? The LP one is $450 or so which is more palatable than the factory's 750 or so. I'm guessing a local muffler shop could put it on in an hour.

edit: I guess stainless vs aluminized is the benefit?

Stock exhaust is not aluminized steel. It is like 409SS. The LP one is 304SS so will likely last longer. I'm hesitant to say "the life of the car" because flex sections are prone to failure eventually. But the stock makes a racket and didn't last me but 2 years! The replacement (revised version) is slightly different but the flex sections look the same--just that the location on the pipe is slightly different. Some have reported that the revised part failed, which is why I went with Lethal. It can be installed yourself and I haven't had a lick of problems with it.

 

[waubrey600]

Check ur timing chain

Cam phaser for timing chain. No recall on this yet. Dealers have been notified of the potential problem with a service bulletin. If rattle lasts for more than 15 seconds upon cold start, then you have a problem. I have 46,000 on my 2020 Explorer. Mine will rattle for 45 seconds, then settle down. Check NHTSA for Ford Explorer engine problems, and make a report.

 

[peterk9]

Cam phaser for timing chain. No recall on this yet. Dealers have been notified of the potential problem with a service bulletin. If rattle lasts for more than 15 seconds upon cold start, then you have a problem. I have 46,000 on my 2020 Explorer. Mine will rattle for 45 seconds, then settle down. Check NHTSA for Ford Explorer engine problems, and make a report.

Welcome to the Forum.

Peter

 

[parulfojii]

I'll take it to another dealership but first, I will demand them to have this 'normal' sound replicate on one of the other STs they have sitting on their lot. Don't think that will happen - LOL!

 

[peterk9]

I'll take it to another dealership but first, I will demand them to have this 'normal' sound replicate on one of the other STs they have sitting on their lot. Don't think that will happen - LOL!

Welcome to the Forum.
I have sent you a Private Message.

Peter

 

[breddy]

This issue has cropped up on our 2020 ST. The TSB clamp solution fixed it for some time but it's back. Dealer said it's the flex pipe and what he described is exactly like what's in this video:



We're out of factory warranty and the parts are over $700. Fidelity won't cover it (exhaust excluded). My question is what is the benefit of the LP mid pipe other than to just replace the Ford one? There's no resonator delete or anything, right? The LP one is $450 or so which is more palatable than the factory's 750 or so. I'm guessing a local muffler shop could put it on in an hour.

Had a local muffler shop weld in some new flex pipe and that did not resolve the issue. I'll try to get a better recording of the sound. Definitely seems to emanate from the passenger floor so I don't think it's the timing chain? But I'll verify to be sure. Any recordings of what that sounds. like?

 

[breddy]

Cam phaser for timing chain. No recall on this yet. Dealers have been notified of the potential problem with a service bulletin. If rattle lasts for more than 15 seconds upon cold start, then you have a problem. I have 46,000 on my 2020 Explorer. Mine will rattle for 45 seconds, then settle down. Check NHTSA for Ford Explorer engine problems, and make a report.

Lots of videos out there on the 3.5 with this issue ... not much mention on the 3.0. Do you think this is an emerging issue with the 3.0EB?

 

[waubrey600]

Hi, our 2020 Explorer ST is currently in the shop due to a loud rattling noise when the cold engine is started. This did not occur when the vehicle was new but I was just notified by the dealership that this would be 'normal'. Does your vehicle make this sound, too?

Rattling Sound

Thanks in advance!

My 2020 twin turbo started this at 42000 miles. Took it first to my local mechanic, whom I trust, for a diagnosis. On cold start. I thought it sounded like exhaust clamp rattling. He said NO. SAID WAS CAM ADJUSTOR, and there is a service bulletin from Ford on this.
Gave me copy. His advice was, MAKE FORD FIX IT, THEN SELL IT!
Ford dealer after two visits says it is normal rattle. But could not duplicate on other used like vehicles on their lot.
Going to another dealer! My local dealer has lost my business!

 

[breddy]

My 2020 twin turbo started this at 42000 miles. Took it first to my local mechanic, whom I trust, for a diagnosis. On cold start. I thought it sounded like exhaust clamp rattling. He said NO. SAID WAS CAM ADJUSTOR, and there is a service bulletin from Ford on this.
Gave me copy. His advice was, MAKE FORD FIX IT, THEN SELL IT!
Ford dealer after two visits says it is normal rattle. But could not duplicate on other used like vehicles on their lot.
Going to another dealer! My local dealer has lost my business!

What's the TSB number?

edit: this? 22-2377 Ford Technical Service Bulletin