Good morning everyone.

So I added the Pypes headers to my 2007 V6 with the Ford True Dual Exhaust with GT-B mufflers.

That's when the fun started.

I had them professionally installed.

When I brought it home the first time it sounded like an offroading truck from time to time at idle. Brought it back. They told me it was a header leak and when the engine torqued bla bla bla. They fixed it. No more monster truck undercarriage sound.

Then yesterday when I'm tooling around I start to get a rattle? ticking? from what sounds like under the shifter / behind the radio.

So up it goes on the ramps. I'm tinkering around checking all the joints. No issue. All are ludicrously tight and have been spot welded. I'm womping on it with a rubber mallet looking for a reverberation. Only when I rapped them good did I hear a vibration but I'm sure any pipe smacked hard enough will make some noise.

I'm running my hands up and down the pipe and can't feel any points of contact or anything reasonably close.

I'm running the flashlight all under the undercarriage looking for telltale rubbing or impact marks. No dice.

I remember reading that the back of the driver's side rear hanger is too long and will hit the bumper at times. Ok. I take the sawzall and take a bit off the back of the hanger so there's no way it can hit the bumper. (Note that the sound was before I clipped the piece) Still that stupid sound.

Everything is tight. Everything is tacked. There are no rub marks. Am I losing my mind? I had hoped to avoid crap like this by buying a Ford designed product but it looks like that isn't the case.

I don't know if it affects the price of tea in China but I installed a CDC Shaker. Tight as a button. I'm also running a Bama tune fluctuating between the 87S and 87P tunes. I do notice my RPM's idling at 500-600. It idles pretty smooth but I've also read of people upping their RPM's to 800 at idle with the tune and it kills the rattle.

Please help. At the next rattle I'm just going to rap myself in the head with the mallet.

 

any tips that anyone can offer for whatever they did with their system regardless if it's the same problem as mine would be helpful as i know i'm going to have to sleuth this out inch by inch.