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2009 F-150 Drivetrain noise

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I purchased a new F-150 this past May and am experiencing a noise in the drive train. It was first noticed at around 400 miles and it is still present at 1600 miles. I suspect it is the trans, but don't know for sure. I also realize the vehicle is under warranty, but the dealer wants to do exploratory surgery which I am not willing to let them do on my NEW vehicle at this time. Since the "check engine" light is not on, there are no DTCs. The noise is a higher frequency metallic ticking noise that only occurs under the following conditions:

Both engine and trans temp gauges must be at normal operating temperatures (until then, the vehicle is quiet).

Vehicle must be in gear and under load (forward or reverse) for noise to occur. Makes no noise in park or neutral or in gear with the vehicle jacked up off the ground.

Noise starts just off idle and can be heard up to a least 35 mph.

Noise will stop when you take your foot off the gas pedal.

You can gently brake torque the vehicle and make the noise occur.

If you shut off the vehicle for any period of time, both gauges have to come back up before the noise will start again. The reason I believe it is the trans is becasue the engine temp gauge comes up way before the trans does and that is when it starts. Also, the only thing I am aware of that happens at normal op temps is the thermostatic bypass valve opens in the trans to circulate the fluid. Is it possible that the valve is the problem? Could it make this much noise? I am embarassed to drive my new truck down the side street because of the noise.

My dealer has not heard this noise before and they contacted Ford who said the same. Any thought????

Thanks.
 
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I just realized that I left out three key pieces of information in the original post above: The vehicle is a supercab with the 4.6L 3-valve engine and the 6R80 transmission. (Couldn't figure out how to edit the original post, if that is even possible).

Thanks.
 

blacksnapon

Moderator
Staff member
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waynesville,mo.
Hmmmm,That one is interesting.... You said you can brake torque it, is that moving or stationary? There is a tool to assist in finding noises. Ask for them to use the "Chassis ear"
 
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Blacksnapon,

Brake torque the vehicle stationary. I would think that would eliminate a lot of the transmission because most of it isn't rotating if the vehicle is not moving. Also, that eliminates the driveshaft and axle.

Tooly
 

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