2001 windstar tapping banging from black upper intake

I am trying to figure out how to fix an odd tapping noise from a 2001 ford windstar with about 110,000 miles. It has gotten very cold here, less than 20 degrees, and my friend called yesterday and said the van was making noise.

I just got back from there. At first it didn't sound like anything bad. Then a heavy tap from the top like something was loose. Not the usual valve noise I am used to from older engines. I took off the black intake and did not see anything special.

I have heard about the intake rattle bushing problem and this dose not sound like that at all to me.

I can feel the tap like I am right on top of it when I touch the upper intake plenum.

This van ran perfect and all of the suden this sound. I am at a loss and looking for help from someone more familiar with this engine.

I forgot to add that if I rev it to a steady rpm and let off it bangs more and then steadies out. It sounds like something is loose and has to catch back up with the movement of the other parts in the engine. The noise is not constant. It comes and goes. When it goes away it is gone completely. This comes right back.

Is it the 3.8 or the 3.0 engine???

Does it misss?

Any codes???

Can you make a video and post?

Is it the 3.8 or the 3.0 engine???

Does it misss?

Any codes???

Can you make a video and post?



I think that they offered the 3.8 in that year so it is a 3.8 liter. It seems to run perfect and I did not see any codes.

I will try and get over there tomorrow and drive it and make a video.

It sounds like the baffle that's inside the upper intake plenum is loose and making noise when the engine runs.

Take a look at this picture from my '00 3.8 upper-intake manifold project:

http://smile.webshots.com/smiles/849ddb60faf1012fe98412313f013977

The piece in the middle is the baffle. It fits between the two halves of the upper intake manifold, and helps direct airflow within the plenum. There are no separate fasteners holding the baffle in place; it simply fits tightly between the two halves. However, I've heard that it can get loose and begin rattling; I suspect this is what you're hearing.

I've read of people using RTV (fixed typo) or other materials to keep the baffle from rattling. If you add anything, make sure it's done in a way that nothing can get loose and be ingested by the engine. You'll have to pull of the top cover of the upper intake manifold to get to the baffle, but this isn't a terribly difficult job.

It sounds like the baffle that's inside the upper intake plenum is loose and making noise when the engine runs.

Take a look at this picture from my '00 3.8 upper-intake manifold project:

http://smile.webshots.com/smiles/849...8412313f013977 (http://smile.webshots.com/smiles/849ddb60faf1012fe98412313f013977)

The piece in the middle is the baffle. It fits between the two halves of the upper intake manifold, and helps direct airflow within the plenum. There are no separate fasteners holding the baffle in place; it simply fits tightly between the two halves. However, I've heard that it can get loose and begin rattling; I suspect this is what you're hearing.

I've read of people using PVC or other materials to keep the baffle from rattling. If you add anything, make sure it's done in a way that nothing can get loose and be ingested by the engine. You'll have to pull of the top cover of the upper intake manifold to get to the baffle, but this isn't a terribly difficult job.

I had that top cover and the baffle off yesterday. I am going to check it out again but from what I heard it sounds like more than a plastic baffle. I really hope it is though. I sounds scary to shove something in there to keep is from comming loose. How have others done this? I will make a video this time.

I also agree with the loose baffle idea. Once you see where it is loose, a bead of RTV will surely help slow down the oscillations ... and should not be dangerous, at all. Just let it cure very well.

I also agree with the loose baffle idea. Once you see where it is loose, a bead of RTV will surely help slow down the oscillations ... and should not be dangerous, at all. Just let it cure very well.

The more I think about it the more it makes sense because if you touch that upper black cover it feels like you are right on it. This noise was loud at times which is the only thing that make me think that this is not the issue.

If there is anyone who has expericened this exact problem, how loud way yours?

Ugghh: Note that I fixed my post above; I said "PVC" when I meant "RTV".

Yes, I believe a small amount of RTV - on a carefully cleaned surface, and allowed to fully cure - would work fine.

Later edit:

Here's an earlier thread that includes the experiences of someone who RTV'd their baffle:

www.automotiveforums.com/vbulletin/showthread.php?t=1013822

I looked at the car today and it made no noise at all. I was told it was tapping earlier in the day. It was allready warm when I got there so maybe that is why it was quiet when I ran it.

The baffle on my van broke a few years back and I replaced it with a new 1 piece design. Found it on ebay for about $60. Easy job to replace.

had the same problem with my 2001 windstar...replace the upper plenum cover