Knocking noise coming from the passenger side catalytic converter area

Tiny
BREEZEFFA
  • MEMBER
  • 2003 FORD F-150
  • 5.4L
  • V8
  • 4WD
  • AUTOMATIC
  • 175,000 MILES
Alrighty y’all. My truck listed above has been making a knocking sound since September. I know for a fact it’s not a rod knock. The sound is coming from my passenger side catalytic converter area. Any ideas? I was told it’s a bad catalytic converter
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Wednesday, March 3rd, 2021 AT 6:00 PM

25 Replies

Tiny
MHPAUTOS
  • EXPERT
Hi there,

We need to determine if the catalytic converter is defective, the link below will assist with testing if this is the case. the most common problem is that the matrix collapses and this can rattle and knock inside the exhaust.

The link below will assist with testing the converter.

https://www.2carpros.com/articles/how-to-test-a-catalytic-converter

https://www.2carpros.com/articles/bad-catalytic-converter-symptoms

Mark (mhpautos)
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Thursday, March 4th, 2021 AT 5:27 AM
Tiny
BREEZEFFA
  • MEMBER
Okay, thank you. Do you think that noise would sound like a catalytic converter? I ll do those test as well later today.
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Thursday, March 4th, 2021 AT 8:15 AM
Tiny
MHPAUTOS
  • EXPERT
If you can post a short video clip of the noise that may help me determine what it may be.
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Thursday, March 4th, 2021 AT 8:21 AM
Tiny
BREEZEFFA
  • MEMBER
So I put my ear up to the catalytic converter and I could hear it more there, than around my engine.
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Thursday, March 4th, 2021 AT 12:03 PM
Tiny
BREEZEFFA
  • MEMBER
Here is the video:
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Thursday, March 4th, 2021 AT 12:03 PM
Tiny
ASEMASTER6371
  • EXPERT
Good morning,

If that is coming from the converter, the insides of the converter are melted and loose and they are moving around internally. The converter will have to be replaced.

https://www.2carpros.com/articles/catalytic-converter-replacement

There was a TSB for knocking which I posted below as well.

Roy

TSB 04-20-6

10/18/04

TICKING OR KNOCKING NOISE COMING FROM THE
CATALYTIC CONVERTERS

FORD:
1997-1998 F-250 LD
1997-2003 F-150

ISSUE
Some 1997-2003 F-150 vehicles equipped with any engine, and 1997-1998 F-250 LD vehicles equipped with the 5.4L engine, may exhibit a ticking or knocking noise coming from the catalytic converters. The noise may be described as sounding like a diesel engine. The condition will be present when the vehicle is in gear at idle only, and is more pronounced when the vehicle is stationary, such as sitting in a drive-through line. The noise is normal, and is created by engine pulses being amplified through the light-off converters.

ACTION
DO NOT replace converters unless loose internal components are found. To reduce the noise, install a wrap kit on each of the light-off converters. Refer to the instruction sheet included in the kit.

WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage

imageOpen In New TabZoom/Print

Parts Block

OPERATION DESCRIPTION TIME 042006A Install Wrap Kit On Both 0.7 Hr. Light-Off Converters (Includes Time To Perform Road Test)

DEALER CODING
CONDITION BASIC PART NO. CODE 5E212 42
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Monday, March 8th, 2021 AT 2:46 AM
Tiny
BREEZEFFA
  • MEMBER
Thank you very much.
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Tuesday, March 9th, 2021 AT 8:14 PM
Tiny
ASEMASTER6371
  • EXPERT
You are welcome.

Always glad to help.

Roy
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Wednesday, March 10th, 2021 AT 2:57 AM
Tiny
BREEZEFFA
  • MEMBER
So should I replace my converters to get rid of this noise?
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Thursday, March 11th, 2021 AT 6:44 AM
Tiny
ASEMASTER6371
  • EXPERT
Correct. The inside is broken into solid chunks.

Roy
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Thursday, March 11th, 2021 AT 7:49 AM
Tiny
BREEZEFFA
  • MEMBER
I replaced the catalytic converters, still have the knocking sound.
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Sunday, April 11th, 2021 AT 5:39 PM
Tiny
ASEMASTER6371
  • EXPERT
Can you upload a new video a little longer with the noise?

Roy
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Monday, April 12th, 2021 AT 4:08 AM
Tiny
BREEZEFFA
  • MEMBER
I don t have another video currently, but it sounds exactly like the original video. It has quieted down a little since I put some lucas oil stabilizer in, but I m still unsure what the knock is.
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Tuesday, April 13th, 2021 AT 12:10 PM
Tiny
ASEMASTER6371
  • EXPERT
The video was so short, I barely heard the noise.

I would have the oil pressure tested manually to be sure it is not an oil pressure issue.

https://www.2carpros.com/articles/engine-noises

Roy
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Tuesday, April 13th, 2021 AT 12:23 PM
Tiny
BREEZEFFA
  • MEMBER
I can get you another video tomorrow if that works.
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Tuesday, April 13th, 2021 AT 7:03 PM
Tiny
ASEMASTER6371
  • EXPERT
Yep, that will work.

Roy
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Wednesday, April 14th, 2021 AT 12:14 AM
Tiny
BREEZEFFA
  • MEMBER
Sorry for the late response. Here is a video where you can really hear it.
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Thursday, April 29th, 2021 AT 8:54 AM
Tiny
BREEZEFFA
  • MEMBER
Here is another, it s not as loud here.
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Thursday, April 29th, 2021 AT 8:54 AM
Tiny
ASEMASTER6371
  • EXPERT
Thanks for the video.

That is internal engine noise. It could be lifters or bearings.

I would suggest replacing the engine with either a used or rebuilt engine.

Roy
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Thursday, April 29th, 2021 AT 10:51 AM
Tiny
BREEZEFFA
  • MEMBER
That is way too expensive for me, lol. I was told there was a TSB on the noise? It gets really quit after the engine warms up as well.
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Thursday, April 29th, 2021 AT 2:14 PM

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