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Old 06-10-2021, 02:31 PM   #21
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Just another thought, but driveline noises relative to load or throttle application have unique signatures. I have a Ranger that lost pinion preload in the rear end and it makes all sorts of racket under trailing throttle at high speeds...nothing anywhere else. I wouldn't discount worn gears or rear end parts.

Also, my cat was stolen years ago and I drove for 2 years with a straight pipe with zero drone. I do have a flowmaster 70 series muffler which also doesn't drone (all of this on a v10).

Scott
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Old 06-10-2021, 05:28 PM   #22
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Talked to a Ford Tech about removing the resonator from the 7.3 intake. He advised against it as the resonator was there to defeat a harmonic drone. I suspect your custom intake did not leave a resonator in place?

Could be the issue with the noise.
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Old 06-12-2021, 05:48 AM   #23
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Pull the doghouse and check the clearance of the exhaust against the doghouse opening or for any other contact with anything, that will certainly make a racket. Is it a stock exhaust? Not just the muffler, but larger pipes?
Iíve got very little clearance with my 4Ē pipes from the turbo on the 7.3, I had some work done where the exhaust flange clamp at the turbo had been loosened up and I noticed a droning afterwards. Once the pipe had heated up and expanded from driving, it made contact with the metal pinch seam along the doghouse opening that created an unusual amplified sounding drone at just the right resonance, I had to loosen the flange clamp and pry the exhaust away just enough from making contact before retightening things. Check clearance and signs of any exhaust contact
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Old 06-13-2021, 12:57 PM   #24
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Pull the doghouse and check the clearance of the exhaust against the doghouse opening or for any other contact with anything, that will certainly make a racket. Is it a stock exhaust? Not just the muffler, but larger pipes?
Iíve got very little clearance with my 4Ē pipes from the turbo on the 7.3, I had some work done where the exhaust flange clamp at the turbo had been loosened up and I noticed a droning afterwards. Once the pipe had heated up and expanded from driving, it made contact with the metal pinch seam along the doghouse opening that created an unusual amplified sounding drone at just the right resonance, I had to loosen the flange clamp and pry the exhaust away just enough from making contact before retightening things. Check clearance and signs of any exhaust contact
Do you have any pictures of your down pipe with the doghouse off?
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