E 350 V8-4.6L SOHC VIN W (2005)
Catalytic Converter: Customer Interest
Exhaust System - Muffler Rattling/Fluttering Noises
TSB 08-21-12
10/27/08
MUFFLER RATTLING / FLUTTERING TYPE NOISE
FORD:
2005-2006 E-Series
ISSUE
Some 2005 E-Series vehicles equipped with a 4.6L engine or 2005 - 2006 E-Series vehicles equipped with a 5.4L engine may exhibit a muffler rattling /
fluttering type noise from the muffler while driving and / or accelerating. This may be caused by pieces of broken catalyst being caught in the body of the
muffler.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Inspect and replace the catalyst and muffler assemblies using the following steps.
1.
Inspect the exhaust system for loose components such as heat shields and hangers. Tighten as required.
2.
Start vehicle, lower driver's side window, and slowly raise engine idle, with transmission shifted into park position, to 1800 RPMs.
3.
Listen for a rattling/fluttering noise.
a.
If rattling/fluttering noise is heard, shut vehicle off, continue to Step 4.
b.
If no rattling/fluttering noise is heard from the muffler, the procedure does not apply. Do not continue and perform normal diagnostics.
4.
Remove muffler assembly. Refer to Workshop Manual (WSM), Section 309-005. Shake muffler with inlet pipe of muffler pointing towards the
floor.
a.
If light colored sand like substance falls from inlet pipe of muffler, replace both the muffler assembly and catalyst assembly. Refer to WSM,
Section 309-00.
b.
If no light colored sand like substance falls from inlet pipe of the muffler, this procedure does not apply. Do not continue, perform normal
diagnostics.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.
OPERATION
DESCRIPTION
TIME
MT082112
Use SLTS Operations If
Actual
Available; Claim Additional
Time
Diagnosis Or Labor
Performed As Actual Time.
DEALER CODING
