Rattles and Unexpected Noise

[skullandbones]

I didn't expect to have any rattles in my new ride but I do have a few. At first I didn't think too much about it but now I've spent some time in the seat for about 1600 miles. One seems like it is in the dash area but I can't tell for sure. The only think I can think is I may have the rearview mirror screws pulled down enough to allow the body to touch the metal dash bow when I hit something hard. I think I found a couple others. One was a sheet metal sound that only happened at certain rpms. When I put it on the lift I found two holes without bolts in the metal plate between the engine and bell housing. I can't remember if I didn't install them or if they worked their way out (locktite). No more sheet metal sound. Then there is the occasional clunk when I turn hard to the right. I found that one too. It was the plug of the O2 sensor hitting the fiberglass body. I thought I had secured it. There wasn't much play anyway but just enough to act like a clapper in a bell when I turned right. Of course, I am constantly listening for anything different. I've also been reading about people's experience when they change things like suspension parts that can produce noise that you would not expect normally such as with spherical rod ends. I've done a lot of mods and changes to the suspension and there's no weird noises coming from there, thankfully. Also, the tires I picked for the first round after the "hot rod" experience which is another story, are nearly perfect. There is hardly any space left at the fenders but just enough with the limited travel to get no rubbing sounds coming from the wheel wells. So now only the soft whine from the PS pump can be heard from the engine bay which I have heard is common with the Mustang donor pumps. It's not that bad. I can hear the dual fans when they chime in at 185 degrees but it's only because I know they are supposed to at that temp so I'm waiting for it. It's surprising to be able to hear anything over the side pipes and engine noise but I guess you get used to it after a while. I do have a donor T5 and Cobra diff but both had around 60k on them and they make no unnatural sounds or whines. So are there any other sounds that I should be listening for???:confused:

Thanks,

WEK.

[Jester]

Nice update.

I have approx 1000 mi on my fully completed MK4 this year (total approx 3500mi). I am also tracking down a few new squeaks. I have a similar squeak to you that is driving me nuts but I think I have found the source - coming from the side pipe hanger bolt. Since repairing the stress cracks in the side pipe hanger and adding a 1/8 inch oval SS plate to reinforce the hager area (other previous post) the use of only 1 hanger bolt for the side pipe hanger allows the side pipe to rotate on the hanger (over bumps or acceleration). I plan to install a Teflon washer on the bolt between the hanger and the side pipe. It has been a process of elimination but I think this is the source of my squeak. I now realize the amount of repetitive stress put on the side pipe hanger mount and no surprise stress cracks develop in the side pipes with the 2 hanger bolt setup (no where else for the stress to go but into the steel around the hanger mount on the side pipe) I am running a J-pipe but I think similar stress would be seen with the 4 into 4 exhaust given the stress is related to the forces on the pipe near the hanger. If running 4 into 4 - I have read some builders do not use the side pipe hangers.

I was going to post an update after I eliminated my squeak but hopefully this is it - hope this is not a wild goose chase.

One other source of a squeak may be the fuse panel - as long as it is tight - did not seem to be the source of my squeak.

Please post an update re your squeak as others like me are going through the same thing.

[CraigS]

Be sure you have clearance around the windshield posts so no fiberglass to post contact. that one drove me crazy for a while.

[skullandbones]

Craig,

What sort of noise were you experiencing with the windscreen post hitting the body? I'm still not sure what is generating the klunk when I hit a bump in my dash area. So I need to know what you heard to see if that could be it. This reminds me of when people go to a mechanic and describe the new sound their car is making. It doesn't always translate the first time when you describe the experience with someone. Oh well. WEK.

[Jester]

Not sure if this helps but what you are describing might be caused by the side pipe hangers if are too close to the body they will hit the body over bumps. I installed 4-5 inch long piece of hard rubber hose as a sleeve over the hanger to stop any abrasion against the body. I noticed this during shake down last year.

[skullandbones]

I'll have to check that again when I put it up on the lift. I thought I had plenty of clearance there but will check anyway. I did the one bolt attachment to the side pipes also. I had heard so many horror stories about the mount cracking. I also have 4 tube headers so it isn't exactly the same as yours was but I still think it could cause a failure from not being flexible enough to let the hanger float without torqueing the mount when accelerating and bumping. The noise I'm most bothered by is the one in the dash area when I hit a hard bump or washboard street like we have in our little "main street" town. But when you get rid of one noise that opens the door for another less bothersome one to take it's place! Thanks, WEK.

[billjr212]

Haha. I like the potential of this thread. One more to watch out for that drove me nuts for months until a late night drive revealed the headlight was loose in the bucket. Those silly little aluminum clips bend loose over time and cause the headlight to rattle/clatter/bang depending on the road surface. At first, it seems more like a suspension noise, but fixed the clips and voila- no more noise.

A quick 2 finger tap on your headlight in a few different angles should reveal if it's loose. Don't push too hard or you'll bend the clips yourself.

[Jester]

I have lubed the side pipe hangers, checked the window pillar openings and cover plate, lubed the front end suspension, re-tightened the J-pipe bolts, double checked the fuse panel bolts and I still have the squeak. Seems like something rubbing against an aluminum panel below the dash or inside the door - but could be anything. I will re-tighten the seat bolts then spray rust-check in the door. After that it's a complete bolt check to find the source.

A good thing is the steering is significantly lighter after a good grease job on all nipples (I don't think I ever greased the tie-rod end nipples - dohhhhh! - no wonder parking maneuvers were previously a challenge - much much easier now!)

[Jester]

I have lubed the side pipe hangers, checked the window pillar openings and cover plate, lubed the front end suspension, re-tightened the J-pipe bolts, double checked the fuse panel bolts and I still have the squeak. Seems like something rubbing against an aluminum panel below the dash or inside the door - but could be anything. I will re-tighten the seat bolts then spray rust-check in the door. After that it's a complete bolt check to find the source.

A good thing is the steering is significantly lighter after a good grease job on all nipples (I don't think I ever greased the tie-rod end nipples - dohhhhh! - no wonder parking maneuvers were previously a challenge - much much easier now!)

Update: The source of my squeak has been tracked down and eliminated - related to J-pipe to header socket connection on DS - used high temp lube on the connection and squeak is gone - finally.

[skullandbones]

I think people automatically associate rattles with poor quality so it bothers me to hear one on my ride but since this is the shake down period for mine, I consider it normal. One thing that has gotten my attention is the potential for adding even more rattles, squeaks, and unnatural sound in the car is the addition of spherical rod ends and other components for suspension mods. I have heard accounts of how the joints cause all sorts of noise in the name of improving the handling. I'm going in that direction so I will have to be careful not to add some more gremlins!!!

WEK.