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I just got back from my SVT-Certified Ford dealer where I bought my 2004 SVT Focus 4 door hatchback where I bring it for occasional service regarding the rattling noises I'm getting at low RPMs. mostly in 2nd gear.

The first time I brought it in to my dealer for the same problem was about a year ago, and they told me that it wasn't a major concern, and if I wanted to fix it it would cost about $220; at the time I had no information about it.

Today when I brought it in, I mentioned some of the things I read on these forums of what it could be: the heat shield or the throw-out bearing. When I got the call back an hour later, they told me that it was indeed the heat shield causing the noise and they were ordering the part(s) needed which will arrive in 4 business days or so. She said that it wouldn't cost me anything because it was covered by Ford Warranty (or something like that, I don't remember exactly what she said) but I was pretty happy about it.

If anyone else is having a similar problem which it seems like according to these forums, find out if your dealer can cover it for you. If you want me to scan the receipt when I get it repaired next week, I can do that.
 

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Mine used to rattle like crazy, until I clamped the heat shield on top of the cat (the one directly under the engine) down. Cost me $8 in clamps.
Just last night I fixed another rattle. The big heat shield that wraps around the header was rattling at the bottom. Bent it so it won't rattle anymore. Cheap as freeeeee. :p
 

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Mine was rattling as mentioned above. I removed the header heat shield. Still rattled. Removed the cat heat shield, both upper and lower. Still rattled. Got so disgusted with it, thought it might be a cat mounting bracket. Took it to an exhaust shop. $35 later I was satisfied as there was no more rattle. A month later, the rattle was back. Went to the Ford dealer in defeat, to pay their price to fix it. The service writer calls me back, tells me that the cat is bad, and that they will replace it under warranty, even though the car is no longer under warranty. They mounted it using the new cat bracket too.

No rattles now, and I am very happy.
 

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Mine rattled too but I took some washers and put them btween the bolts to get rid of it. It's common and there is a tsb on the heat sheild bolts holes wearing and causing the shield to rattle. Also the cat mounting braket tends to crack too and the mounting points, there's also a tsb on that as well.
 

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so ford will fix the issue free of charge ??? is the fact that its listed in the TSB be the reaason ?
 

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No, i doubt Ford will fix it free of charge. There must've been a reason he had it fixed for free if he was out of warranty.

If anything, it was probably the cat bracket that broke and they thought they had to replace the whole thing. And since i believe most states have a seperate emmissions warranty, that's what the dealer used to fix the rattle.
 

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hmmm i'd hate to pay $200+ for a dealer to tighten a couple bolts... i can have my mechanic do that for me, but im just not sure wats ratteling exactly...
 

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WD-40 had a similar issue but he ended up swapping the exhaust shield for a new one, his was broken... the part is $30 and its fairly easy to bolt it up... but again, theres no way to find if it is in fact the shield, or a throw out bearing, or driverside engine mount... god knows
 

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mine rattled for a while too. i had an exhaust guy look at it and he couldnt find where it was rattling. then one day i got a car wash that sprayed my underbody as well.... and to this day no more rattle. Confusing but im not gonna complain.
 

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will replace the shield in the next few days, see if that cures it, im 90% sure its the cause of the rattle...we'll see [wrenchin]
 

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check your cat bracket mine was rattling only on take off.it was broken
 
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