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Discussion Starter #1
So after owning my truck for close to 1 year now I have finally lost all patience with dealing with the faint to annoying rattling (sounds like a tin can or something) coming from the underside of the truck at or right below 2100 RPM. Once I pass 2100 or come back down from 2100 it completely goes back to normal sounding. Performance has not been lost and the truck is getting average mpg so idk if it's my cats. Thing is it only happens when the truck is in gear and under load, ie up a hill or getting on the highway or pulling from stoplight etc.

It was present when the truck had the stock muffler on, so i didn't think anything of it, thought it could be the stock muffler with a broke baffle weld or a loose heat shield. I then switched to a FM40 and the sound was still present. After dealing the massive drone a FM40 has I switched to a Aerotrubine 3030xl and it is now worse than ever. I have tightened every accessible heat shield bolt/screw and tightened. My U-Joints look fine (thought it might be them straining under that particular rpm). I even went as far to take my stock manifold heat shields off as I thought they were causing the problem (one had a broke stud and the heat shield would bounce around). But that didn't help the problem at all.

Everything I am reading is saying that it's the muffler but seriously? What's the chances of having 3 different mufflers within a year, all 3 of which with busted muffler welds? I think not...

I had a 96' Ram that I had to get my cat replaced because it would rattle almost identically sounding but only at idle ~650 rpm. My truck now doesn't have this problem at idle. ONLY at 2100 rpm under load and in gear. SO..with all that being said is anyone experiencing the same problem I am? Any suggestions on things to check? Is there anyway to check the cat's externally before taking them to muffler guy and having him charge me $$$ I don't want to spend?

Thanks a bunch for the input guys!
 

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So after owning my truck for close to 1 year now I have finally lost all patience with dealing with the faint to annoying rattling (sounds like a tin can or something) coming from the underside of the truck at or right below 2100 RPM. Once I pass 2100 or come back down from 2100 it completely goes back to normal sounding. Performance has not been lost and the truck is getting average mpg so idk if it's my cats. Thing is it only happens when the truck is in gear and under load, ie up a hill or getting on the highway or pulling from stoplight etc.

It was present when the truck had the stock muffler on, so i didn't think anything of it, thought it could be the stock muffler with a broke baffle weld or a loose heat shield. I then switched to a FM40 and the sound was still present. After dealing the massive drone a FM40 has I switched to a Aerotrubine 3030xl and it is now worse than ever. I have tightened every accessible heat shield bolt/screw and tightened. My U-Joints look fine (thought it might be them straining under that particular rpm). I even went as far to take my stock manifold heat shields off as I thought they were causing the problem (one had a broke stud and the heat shield would bounce around). But that didn't help the problem at all.

Everything I am reading is saying that it's the muffler but seriously? What's the chances of having 3 different mufflers within a year, all 3 of which with busted muffler welds? I think not...

I had a 96' Ram that I had to get my cat replaced because it would rattle almost identically sounding but only at idle ~650 rpm. My truck now doesn't have this problem at idle. ONLY at 2100 rpm under load and in gear. SO..with all that being said is anyone experiencing the same problem I am? Any suggestions on things to check? Is there anyway to check the cat's externally before taking them to muffler guy and having him charge me $$$ I don't want to spend?

Thanks a bunch for the input guys!
Only thing I can think of is with the catalytic converter because their is something that rattles around inside the converter. Idk if this is your case or not but all I can think of at this second.
 

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Only thing I can think of is with the catalytic converter because their is something that rattles around inside the converter. Idk if this is your case or not but all I can think of at this second.
Yeah, my previous trucks cat had the internal material ball up and melt.

I'm leaning towards the cats as well...
Yeah. That's what I'm feeling unfortunately.

Anybody running magnaflow replacement midpipes with cats and y pipe?? Part number is 49597, 49596 per magnaflow.
 

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hit the cat with your hands (while cold) if the honeycomb is broke you'll hear it. if thats the case it has a federal warranty 8 year or 80k which ever comes first. also check the heat shield around the fuel tank. mine busted off there and was ratteling
 

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Discussion Starter #6 (Edited)
hit the cat with your hands (while cold) if the honeycomb is broke you'll hear it. if thats the case it has a federal warranty 8 year or 80k which ever comes first. also check the heat shield around the fuel tank. mine busted off there and was ratteling
Really??? So should I contact my local dodge dealer? Mine is an 04 with 65k miles, it was built in 2003 so it may be close...when was that federal law passed and what year cars does it include?

I tapped on em with a pair of channelocks and one sounded weird in one spot, like it went from being a thud to a ting. Im assuming they are supposed to sound uniform throughout? May be cat material that has been lost.

I will also check the fuel tank one, I DID overlook that one.

Thanks a bunch 07 2500
 

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Discussion Starter #7
Found it. Clean air act, vehicles '95 and newer, 8 year/80k miles on cats. Wow, I didn't know they had such a critter.

Now with my exhaust being custom from the stock y back, does it interfere or void this warranty?
 

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As for the warranty i do not know taking it to the dealership they may be able to tell you, best bet to be %100 percent sure is use either your hand or a rubber or softfaced mallet and hit the cats, if you hear a rattling the honey comb has broke apart...using the chanel locks is going to create other noise and you will probably not here the rattle
 

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If you have access to a good scanner like snap on or OTC you can see what back O2 sensors are reading the knox will b high
 

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Discussion Starter #11
As for the warranty i do not know taking it to the dealership they may be able to tell you, best bet to be %100 percent sure is use either your hand or a rubber or softfaced mallet and hit the cats, if you hear a rattling the honey comb has broke apart...using the chanel locks is going to create other noise and you will probably not here the rattle
I tried doing this, kinda hard to tell if it's the cat's 100% or if it's the rest of the piping. but it is rattling on both for sure. one thing is for sure it IS NOT a heat shield. i used the mallet on them and they were quiet so it is got to be the cats.

Cat back exhaust will not void that warranty The PCM is also covered since it controls the emissions
sweet!

If you have access to a good scanner like snap on or OTC you can see what back O2 sensors are reading the knox will b high
will your run of the mill code reader be able to do this or is it a specialized reader?

one thing i don't understand is that, why haven't I got a code thrown this entire time? you know? like with the cats failing why isn't there a code being tripped by the two 2 downstream o2 sensors?
 

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So after owning my truck for close to 1 year now I have finally lost all patience with dealing with the faint to annoying rattling (sounds like a tin can or something) coming from the underside of the truck at or right below 2100 RPM. Once I pass 2100 or come back down from 2100 it completely goes back to normal sounding. Performance has not been lost and the truck is getting average mpg so idk if it's my cats. Thing is it only happens when the truck is in gear and under load, ie up a hill or getting on the highway or pulling from stoplight etc.

It was present when the truck had the stock muffler on, so i didn't think anything of it, thought it could be the stock muffler with a broke baffle weld or a loose heat shield. I then switched to a FM40 and the sound was still present. After dealing the massive drone a FM40 has I switched to a Aerotrubine 3030xl and it is now worse than ever. I have tightened every accessible heat shield bolt/screw and tightened. My U-Joints look fine (thought it might be them straining under that particular rpm). I even went as far to take my stock manifold heat shields off as I thought they were causing the problem (one had a broke stud and the heat shield would bounce around). But that didn't help the problem at all.

Everything I am reading is saying that it's the muffler but seriously? What's the chances of having 3 different mufflers within a year, all 3 of which with busted muffler welds? I think not...

I had a 96' Ram that I had to get my cat replaced because it would rattle almost identically sounding but only at idle ~650 rpm. My truck now doesn't have this problem at idle. ONLY at 2100 rpm under load and in gear. SO..with all that being said is anyone experiencing the same problem I am? Any suggestions on things to check? Is there anyway to check the cat's externally before taking them to muffler guy and having him charge me $$$ I don't want to spend?

Thanks a bunch for the input guys!
Did you ever resolve this issue?

Sorry to wake up an old thread but I came across your post in a Google search... I created an account to contact you directly but need a minimum of 25 posts before I can send a PM :doh:

I have checked my entire exhaust (less than 3 years old - JBA Headers, Stage 8 bolts, JBA Y - Pipe, Magnaflow Cat Back and High Flow Cats) and everything appears ok... the tin/rattle/leaky sound is the most annoying noise and it only occurs at 2100 RPM under moderate throttle.

How did you solve the problem? Thanks
 

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Discussion Starter #13 (Edited)
Did you ever resolve this issue?

Sorry to wake up an old thread but I came across your post in a Google search... I created an account to contact you directly but need a minimum of 25 posts before I can send a PM :doh:

I have checked my entire exhaust (less than 3 years old - JBA Headers, Stage 8 bolts, JBA Y - Pipe, Magnaflow Cat Back and High Flow Cats) and everything appears ok... the tin/rattle/leaky sound is the most annoying noise and it only occurs at 2100 RPM under moderate throttle.

How did you solve the problem? Thanks
No problem man, glad I'm still subscribed to the thread. Ha
For me it ended up being a bad cat, so I replaced both the midpipes with new integrated cats from Walker (was my family's parts store's brand for exhaust). NO more rattling, running good. At first I though it was my manifold heat shields, removed both, sound remained.

Might be those cats...? :4-dontknow: Idk man. Haven't had any experience with magnaflow's products. I was leaning towards magnaflow's mid pipes for mine but they wanted more than I was willing to pay for if I remember correctly. Walker's are ok. They weren't mandrel bent, they were ran through a regular tube bender so they are ruffled up at the bends but they have a better y-pipe than stock. 6, half dozen or the other I suppose.

The heat shields above the exhaust down the passenger side of my rig were loose at the time when I was looking as well but after tightening the sound remained, might check those. Our rigs have a bunch of heat shields with foam behind them inbetween the body panel and the heat shield, some of mine was missing as well. Especially around where the manifolds descend into the mid pipes. In your case headers down.

Does that help you any? :LOL:
 

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No problem man, glad I'm still subscribed to the thread. Ha
For me it ended up being a bad cat, so I replaced both the midpipes with new integrated cats from Walker (was my family's parts store's brand for exhaust). NO more rattling, running good. At first I though it was my manifold heat shields, removed both, sound remained.

Might be those cats...? :4-dontknow: Idk man. Haven't had any experience with magnaflow's products. I was leaning towards magnaflow's mid pipes for mine but they wanted more than I was willing to pay for if I remember correctly. Walker's are ok. They weren't mandrel bent, they were ran through a regular tube bender so they are ruffled up at the bends but they have a better y-pipe than stock. 6, half dozen or the other I suppose.

The heat shields above the exhaust down the passenger side of my rig were loose at the time when I was looking as well but after tightening the sound remained, might check those. Our rigs have a bunch of heat shields with foam behind them inbetween the body panel and the heat shield, some of mine was missing as well. Especially around where the manifolds descend into the mid pipes. In your case headers down.

Does that help you any? :LOL:
Thank you for taking the time to respond - I will take my truck to a local exhaust shop and see if they can confirm the cats are the cause of the annoying noise...

I had a feeling it might be the cats and was disappointed to learn they are not covered by warranty. According to Magnaflow the cats are an emissions component and are not covered by the by the lifetime warranty that covers their exhaust components. :4-dontknow:

Another reason I feel it may be the cats is because Magnaflow has changed part numbers since I had my cats installed. Back when I had my exhaust work done Magnaflow listed Part# 99336HM for a 2004 Ram Hemi - the current listing shows Part# 99236HM. Gotta wonder why they now list a cat with different physical dimensions...

Thanks again... I'll post when I get the issue resolved
 

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Thank you for taking the time to respond - I will take my truck to a local exhaust shop and see if they can confirm the cats are the cause of the annoying noise...

I had a feeling it might be the cats and was disappointed to learn they are not covered by warranty. According to Magnaflow the cats are an emissions component and are not covered by the by the lifetime warranty that covers their exhaust components. :4-dontknow:

Another reason I feel it may be the cats is because Magnaflow has changed part numbers since I had my cats installed. Back when I had my exhaust work done Magnaflow listed Part# 99336HM for a 2004 Ram Hemi - the current listing shows Part# 99236HM. Gotta wonder why they now list a cat with different physical dimensions...

Thanks again... I'll post when I get the issue resolved
The integrated cat's that were built into the Walker Midpipes I got were smaller than stock but so far have had no issue with them. As far as them changing the dimension on their product, that does sound a little fishy.

Good luck!!
 

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I have a 2017 Ecodiesel 4x4 with the exact same problem. It sounds like a tin can clanking (but subtle) and only makes the noise between 2,000 and 2,100 rpm while under load...... I had my driveshaft snap and then replaced. The noise was much worse before the driveshaft problem but I did not notice before at what RPM the noise occurred. I know for sure now that it only occurs under load between 2,000 and 2,100 rmp. If I am simply cruising at that RPM no problem. If I am on a hill or accelerating it always occurs at 2000 to 2100 rmp..... If anybody knows the fix please pass on the info. Thanks.
 

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I have a 2017 Ecodiesel 4x4 with the exact same problem. It sounds like a tin can clanking (but subtle) and only makes the noise between 2,000 and 2,100 rpm while under load...... I had my driveshaft snap and then replaced. The noise was much worse before the driveshaft problem but I did not notice before at what RPM the noise occurred. I know for sure now that it only occurs under load between 2,000 and 2,100 rmp. If I am simply cruising at that RPM no problem. If I am on a hill or accelerating it always occurs at 2000 to 2100 rmp..... If anybody knows the fix please pass on the info. Thanks.
Maybe start another thread to get better exposure? Since the previous one was so old.

But...I can tell you my 2017 with Hemi is having a similar issue. Dealer #1 said "resonance" in exhaust or cats. Dealer #2 said "Hemis are noisy, its normal". I tend to believe dealer #1's explanation more, but still not sure either of them are acceptable.

My truck is under factory warranty and I have MaxCare Lifetime, so if it becomes a bigger issue down the road (or really far down the road) I should be covered. If I ever stumble on a fix I will let you know.
 

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Prior to the driveshaft braking the sound was very noticeable and similar to the sound my old Pathfinder made when the catalytic converter was on its way out. I thought for sure it was the same problem. After the driveshaft snapped and was replaced the noise was not nearly as loud so I have basically ruled out the cat (but not completely). There is no doubt it sounds like aluminum rattling and not steel. In fact when I go under the car and tap any part of the exhaust with my fingernail I can duplicate the sound. I take it to the dealer on the 15th of Jan.. I will let you know if they can figure out the problem.
 

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Prior to the driveshaft braking the sound was very noticeable and similar to the sound my old Pathfinder made when the catalytic converter was on its way out. I thought for sure it was the same problem. After the driveshaft snapped and was replaced the noise was not nearly as loud so I have basically ruled out the cat (but not completely). There is no doubt it sounds like aluminum rattling and not steel. In fact when I go under the car and tap any part of the exhaust with my fingernail I can duplicate the sound. I take it to the dealer on the 15th of Jan.. I will let you know if they can figure out the problem.
Sounds good, thanks!

Interesting the driveshaft breaking and being replaced changed the sound. Maybe its something in/on the driveshaft? Or a bad/incorrectly installed u-joint was causing a resonation? My truck has a vibration in the steering wheel, pedals and floorboard right around the same RPM as the sound (2000-2300 RPM), wonder if its related.
 

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On this forum I have read quite a few posts where the truck vibrates. I can not feel a vibration but can hear the rattle. My hope is the driveshaft and the current rattle are not related. I live about an hour from the nearest dealer and breaking down on the side of the road becomes an all day experience.
 
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