Originally Posted by
TurboMedic
I had about 30k on it? maybe 34? I can't recall exactly but I was chasing a heavy throttle shudder between 2-3000rpm. Prominent going up the stoney hill before sarcee if you lock in 7 and roll into the throttle to WOT. I was chasing that since about 21k though, and had to take the shop manager out to replicate it properly because I don't think they ever did. Now, since I've had that fix done it still does it, and I've driven my buddies 17 and it does the same thing, so I think its just a characteristic of the engine. I've changed plugs, regapped, all filters, etc and there was no change.
Now the rattle you're hearing is a BW phaser sound. They have TSB's to "reduce" that rattle but nothing gets rid of it, including changing the parts. There's a giant thread on F150forums about it and some people claim its a bad sound, others (like myself who have experienced it before and after a full swap) feel its not a bad sound. It sounds like like an indexing noise, and it only does it when cold, and goes away when warm. I have videos of my engine making the noise when I had my gopro stuck underneath to see if my IWE's were working right. Its easy to reproduce by lifting off light throttle while driving shortly after startup. Once the engine hits 60 degrees you can't hear it anymore. Engines make lots of noises when they're cold that they don't when warm. Not only that if you listen to almost any ford engine with this style of cam phaser they will all do it (I heard an 06 lincoln I was standing beside start up and it did it too). A number of other manufacturers have the same sounds from theirs.
And your exhaust hole sounds exactly where the drain hole is, and its doing its job not letting moisture sit in the piping. If you're outside when its cold once you can start it and peek underneath, you can see it spitting moisture. As well you can sometimes hear it.