2002 4.0 OHV loud exhaust rattle on cold start

[TechmanDan]

Morning gentlemen.
I'm looking for thoughts, advice, ideas, or any other form of information about the issue i'm having with my '02 Ranger.
it's got 113K Miles, I keep it well maintained, and I recently had to replace the thermostat housing (what a job, beware the rockauto replacement part).
My issue is that when I start it up and it's cold, I get a horrible metal rattling sound, seemingly from the passenger side exhaust system, just in front of the rear wheel.
I have factory exhaust, stock truck, and this issue just presented itself after completing the thermostat housing replacement.
I also flushed the cooling system and refilled it with new fluid.
I don't have a CEL on, no trouble with any fluids I can check, no problems with power or performance.

Thoughts?
-Daniel

 

[monsterchuck]

Crawl under it and pound on the catalytic converter with your fist or a rubber mallet. If it sounds like something is rattling around in there, and you can't find any loose heat shields/and or rocks, it might be a bad converter.

BWT: 2002 4.0 OHV?

 

[TechmanDan]

uh-oh. it'd be a shame to have to replace that, seeing as i'd like to put a better exhaust in it...
A split pipe system with glass packs would be nice.

 

[Downey]

glass pack will sound like shit get a super 44 flowmaster. the exhaust noise is just something that wears out. the exhaust hanger might have broke or a heat shield not a big deal. but if you want a new exhaust that is loud and mean sounding getting a flowmaster super 44. its up to you if you get s/o or d/o and how you run it. most people get d/o and run it out the back or dump it but thats all up to you

 

[TechmanDan]

So tell me more about options. I want something with some growl to it, but I don't want to be the gearhead who wakes the neighbors just because I started the ranger.
I also think i'd like to have fully separate dual pipes... but that means two cats and two mufflers...

Give me some ideas!

 

[TechmanDan]

Well, I found the cause of the trouble. I have a small hole in my muffler from rust. I can only imagine what the inside looks like.
is ok, i'll find someone who likes me and has a welder, and get a new muffler. Such a shame i'll have to put a flowmaster or the like on there...