Front end rattling after transmission was replaced

Hi,

Since you are able to hear it when the vehicle is in park (very quiet), I suspect it is most likely something like a heat shield on the exhaust system. I have even seen the internal components in the catalytic converter come loose and rattle. Also, if it happens when the vehicle is stopped, chances of it being related to a suspension or bushing issue is unlikely.

Here is what I suggest trying: First, take a rubber mallet and tap on the exhaust system. See if you can reproduce the sound. If you hear something, have a helper try to locate the source. I attached a pic of the exhaust system and circled four things. The three at the top are catalytic converters. Although the heat shields are not pictures, they should be on them. The bottom pic I circled is the muffler. Pay attention that that as well.

If there is nothing found and again since it happens when the vehicle is in park, I don't suspect it is a bushing or suspension issue. So, if it is not relate to the exhaust, then we need to remove the serpentine belt, start the engine for a couple seconds, and see if the sound is gone. If it is, then we can assume it is one of the belt driven accessories.

Here are the directions for removal and replacement of the belt. Picture 2 correlates with these directions.

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2002 Ford Truck Explorer 2WD V8-4.6L VIN W
Procedures
Vehicle Engine, Cooling and Exhaust Engine Drive Belts, Mounts, Brackets and Accessories Drive Belt Service and Repair Procedures
PROCEDURES
Accessory Drive Belt-4.6L

Removal and Installation
1. Remove the air cleaner.

See Pic 2

2. Rotate the tensioner clockwise and remove the drive belt.

3. NOTE: Refer to Component Locations for correct drive belt routing.

To install, reverse the removal procedure.

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Let me know if this helps. If you have other questions or need help, please let me know.

Take care,
Joe