My old truck sounds like... an old truck

[locovaca]

Long story short, I bought a 93 3.0 last April, tore it down to the frame and finally have it back together. The truck runs fine, got the timing set, seems to have plenty of power (definitely more than my 2.3), but any time I accelerate it makes an loud, annoying "chugging" sound. Just like in this video:

http://www.youtube.com/watch?v=lT3FMd520dw

I can hear it coming from the floorboards which is why I think it's exhaust related.

I did not do anything wild with the engine while out, just replaced the timing chain/gears and new gaskets, and it does not make the noise at idle nor revving in neutral, only when there is a load on it.

Now for the exhaust work. I did replace the rusty stock muffler and intermediate/tail pipes with a Walker Quietflow SS muffler and Walker pipes. I have a new donut gasket at the cat and used clamps on the pipes at the muffler. I also have new exhaust manifold bolts and gaskets. When I pulled the engine I disconnected the manifolds from the heads but left them connected to the Y-Pipe and Cat because those bolts are pretty malformed now. I can't see any holes in the Cat, Y-Pipe, or Manifolds.

What am I missing? Is the Walker unit a crap muffler? Should I be looking for something on the Engine? Or are the 3.0's really that loud?

 

[tcranger]

in the video that is an exhaust leak. so if yours sounds like that git under the truck and feel around the exhaust for a leak then weld it up

 

[Diesel Ranger]

If your having trouble finding the leak, wait till a realy cold morning and right after you start your pickup a lot of condensation should be pouring out of the exhaust, just glance into the undercarriage and look for steam........

 

[locovaca]

Thanks. After I posted that I ripped out the headers, y-pipe, and cat, cut out the cat studs, and re-gasketed and reconnected it. Still loud but as it warms up it quiets it down a bit, so it might be a crack somewhere.