Rattling sounds at idle after starting engine

Tiny
NCOUNTYLINE
  • MEMBER
  • 2003 FORD F-250
  • 5.4L
  • V8
  • 2WD
  • AUTOMATIC
  • 157,000 MILES
When I start the truck and am in park at idle I can hear this somewhat loud scraping (not grinding) like metal on metal from below. I have gone down to try and locate it but can't pinpoint the location. This is an automatic though I kind of reminds me of clutch plate scraping. I have a very short audio, there is more but I could not upload the file. You will hear it though. In this case it is short, but it can also be drawn out five or six seconds.
Friday, March 18th, 2022 AT 7:13 PM

7 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,643 POSTS
Thanks for the video of the sounds, it keeps the guessing down to a minimum, this noise is common when the start Bendix return spring breaks allowing the starter Bendix gear to contact the flywheel when the engine is running. here is a guide to help you change the starter out with diagrams below to show you how on your truck:

https://www.2carpros.com/articles/how-to-replace-a-starter-motor

Check out the diagrams (below). Let us know what happens and please upload pictures or videos of the problem.
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Saturday, March 19th, 2022 AT 5:51 PM
Tiny
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Thank you for taking the time to respond.
I have had my suspicions about the starter from the outset. The truck was parked outside of my shop space when it would not start. I did a little research and noticed that it could be the relay causing the problem also. So, I ordered a new relay and starter. When you are shopping for 2003 parts it looks like there is an overlay in the years that certain parts will work on. Case in point, several sources said the relay was mounted on the inside of the passenger side wheel well for the 2003 but in my case it is not, it's in the fuse panel.
So, I ordered a second relay and decided to change out the starter. I got the starter ready to drop, only the top bolt left, when the correct relay came in. I plugged it in and dropped the old starter and installed the new one. The truck turned over and started like it always had. However, a minute later I am getting this scraping sound.
After hours on the net looking for an answer I decided I got a bad starter. Emailed the vendor and told them my problem, they assured me their starters were blah blah blah and sent me a new one. I installed it and again the scraping sound. I had to admit defeat that I could not solve this myself and decided to record the sound and put it here since I frequented this site but had, until now, never joined.
Now I am left wondering if the original problem was the OEM starter or relay. Either way, I still have the old starter I am going to clean it up and reinstall it. Two things 1. I am getting pretty good at locating and pulling that top bolt. Lol 2. At least this time I am not in the grass slapping fire ants as I am doing the install. Florida, if it's got six legs, we got it.
I will let you know how this works out. Next starter i'll buy at a local store, advance or AutoZone and bring the vehicle's VIN with me.

Thanks again,
John M
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Sunday, March 20th, 2022 AT 5:07 AM
Tiny
KEN L
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It sounds like you are on the right track, please let me know how it turns out. Stay away from those fire ants!
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Monday, March 21st, 2022 AT 10:21 AM
Tiny
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  • MEMBER
  • 8 POSTS
Today I removed the replacement starter, the second one I put in and after cleaning and greasing the original starter I reinstalled it just to make sure that it was the starter in the first place and not the relay. Truck would not start. It's hard for me to believe I bought two replacement starters and each one had the same problem though I know it's possible. Tomorrow I will reinstall the starter I took out today and I'm going to just sell the truck and declare it to any potential buyer. If I never see another starter again I will be a happy camper; at 71, I think that's a pretty good possibility.
Thanks for the input,
John M
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Tuesday, March 22nd, 2022 AT 4:46 PM
Tiny
KEN L
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Sounds good, good job at 71 getting under the truck to change it out. Can I ask which brand starter are you using?
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Wednesday, March 23rd, 2022 AT 11:07 AM
Tiny
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Hi Ken, I bought the starter(s) off Amazon. I do not know the brand name or if there even is one. Seller is OEG out of Texas. It is not the starter. Today I was looking under the truck to determine where the o2 sensors are located (surprise there is no downstream sensor, only two upstream; one on each side of pipe out of manifold).

While I was poking around down there I noticed that what looked like a heat shield had broken free of the welds that secured it to the exhaust pipe, driver's side. This shield was pressed against the pipe. When the truck started I believe the vibration made the shield drag back and forth just a small amount, enough to create that dragging noise. I guess that when the pipe and shield got hot after startup the shield grew away from the pipe from expansion and the sound went away. I put a hose clamp on and the sound is now gone. In the picture you can see the broken weld, it is broken on the other side as well. Mystery solved and it didn't cost anything! I am so happy I am going to skip the o2 sensors and let the new owner deal with that if they want. Thanks again for the input. Any help offered is always appreciated.
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Friday, March 25th, 2022 AT 10:45 AM
Tiny
KEN L
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Nice work, we are here to help, please use 2CarPros anytime.
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Friday, March 25th, 2022 AT 10:47 AM

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