1996 windstar 3.8 rattling noise

[pjsam]

My 1996 windstar is making a rattling noise. Does anyone know if the intake baffle problem affected the 96 model or was it just later models? Thanks

[busboy4]

Originally Posted by pjsam

My 1996 windstar is making a rattling noise. Does anyone know if the intake baffle problem affected the 96 model or was it just later models? Thanks

HI
The intake was reconfigured on the '99 and newer. The intake baffle rattle we talk about would not be the problem on a '96.

Best regards

[wiswind]

Hard to say what is causing your rattle.....from what you are saying....it sounds like you have narrowed it down to an engine / drivetrain issue and not a suspension issue.

Drivetrain related, could be on the exhaust.....maybe the catalytic converter(s).
FORD had a TSB relative to the heat shields on the catalytic converters breaking loose at one or more of the tack weld joints that hold them in place.
Their solution (I have in my pictures) is to install BIG hose clamps around the converter unit.
Two bands per converter.
Instead of paying the dealer to do that.....I went to the plumbing department at the hardware store....and bought the big clamps that they use for the big plastic pipes....the flexible kind.
So, you will find them near the PVC pipes.....

In my case....it ended up being inside one of the catalytic converters......the ceramic body inside was loose....causing the rattle.
So, the clamps did not help in my case.

Another rattle that I got.....was a small metal shield that is on the transaxle......
You go under the vehicle and look right where the transaxle and oil pan meet......and the shield is mounted to the "bell" housing.....up in between the transaxle and the engine oil pan.
A screw or so was loose......(on the shield....not on me).

I am sure that there are other things that can rattle....but those are 2 that I tracked down for sure.