Hello,

I've got an '03 EB 4x4 Expy and I notice after warm up that I hear a noise in the exhaust system that sounds like a valve or something like an open EGR valve or maybe something loose inside my muffler. The sound is very annoying and I only hear it when accelerating, not at an idle. Also, the noise is not present when the engine is cold. If I had no other way to determine what the problem was, I'd bet it was in the EGR system. Many years back, cars used to have a vent pipe from the EGR valve to the air breather housing. If you removed this hose when the engine was running it made a loud sound like a valve opeining and closing that's in tune with the engine exhaust and this sound I have is just like what I just described.

Anyone else heard this sound in their Expy?

Later,

~DM~

 

Is it a 'ppfftt,ppfftt,ppfftt' sound you can hear coming of the curb when you have the drivers side window down?

 

Ford has a revised muffler assembly that will resolve your noise.

 

Hey Home, thanks for the tip. About when did Ford start putting the improved muffler in production? Mine was built in the middle of Feb 2003.

Thanks again and I hope that's what the problem is.

~DM~

 

Ford's Special Service Message (SSM) covers vehicles built before
06/05/2003

 

I had removed my OEM mufler and put flows on then about 6 weeks later I had this PFFTT,PFFTT noise ...took it in and they tried to say I had a bad weld on the right rear pipe coming out of the flow...I took it home and rewelded the bead...still there... so I rigged up a hose to the wheel well and drove across a closed food lion lot and determined it was a blown exhaust manifold gasket at the #6 cylinder(second from the front drivers side) ...took it back to Ford and they replaced both sides and now no noise...amazing what a little determination on one,s part will accomplish(SC)...wheres that coffee...good luck

 

Yo Tex,

Thanks for the info on your experience, mine may be like yours too. Did your noise happen when cold and hot or just after up to temperature? How long was your truck in the shop for the manifold gaskets?

BTW, what coffee man?

Later,

~DM~

 

it would occure just after start up and last until up to full temp and seem to die down but if I WOT it comes back...in shop for a day...coffee?...look at the time and you did'nt see the spell checks I went through...Steve we need spell check here

 

Yo Tex,

No problem on the spelling chief. Also, what I sometimes do is compose my replies in MS Word, spell check and then paste into the reply box that way I can avoid the really simple words that I tend to goof up on occasion.

Thanks for the exhaust details and your comments. I'm kind of thinking my noise is more from the muffler area and not the engine compartment area but I could be wrong.

Later,

~DM~

 

Skillet,

You were right on the money, thanks bud. The dealer gets my new muffler in tomorrow and then I will have to schedule a day to have it installed along with a bunch of other warranty work they are supposed to do.

Thanks again.

~DM~

 

No worries mon.
We're all here to help each other.

 

I got my new muffler installed and the rattling noise while accelerating went away. Now I've got a new noise from the new muffler. When I crank the engine, the new muffler makes an oil can noise just like you hear when you press the bottom of an old fashioned oiler's can "pun-k-a". After the engine warms up for a few minutes and I'm underway, the muffler makes the same noise again "pun-k-a". I guess when the pressure from the exhuast rises as the engine just starts, the muffler expands and makes the oil can sound and then when it heats up it goes back to the original position then it does it once again.

Damnit, who makes the friggin' mufflers for Ford Expedition?

Back to the dealer again...

~DM~

 

I actually had a fart can installed on your Expy while you were enjoying your steak and baked potato. I thought you'd like it...

 

Rock,

Don't do me anymore favors that involve modifying my Expy...Thanks bud but I may be able to do without those mods.

ppppppppppppppffffffffffffffffffffffffffffffff...

~DM~

 

I tried man... I tried...

Okay, back to your regularly scheduled Expy Muffler thread...

RP