Did you ever solve this? My new TD5 has the same rattle (sounds just like a heat shield rattling) from inside the vehicle at 2500RPM. Would be interested if you ever got to the bottom of it before I start taking things to bits
Cheers
Hello James, no I really never got to the bottom of the noise issue. I checked various heat-shields but none of them were the source. That car has now gone.
However, you might be interested in what I found on my latest TD5 auto another 1999.
Between 2200 and about 2500 I get a noise that I can only describe as a "courseness" in the engine sound. I get this whether I'm in gear or neutral so it must be engine related. I have read that this is quite possibly an indication of the front and rear engine mounts being worn, allowing vibrations to pass into the chassis and therefore the car.
I ordered some rear mounts (because they are loads cheaper) and I will attempt to fit them this week and see if there is any difference.
On a more general front I have learned that the std Torque Converter on pre-facelift (may apply to post as well) is somewhat under specc'd in that in has an inappropriately high stall speed which allows the TC to slip away like a banshee on speed.
Ashcrofts take a v8 TC and modify it's drive plate making it much stronger (therefore more reliable) - the benefits appear to be a much more unified feel to the engine/gearbox combo with less slip and more drive, with better mpg as a result.
My plan is to do this mod and I will replace the triangular flex plate at the same time, so that should quieten things down and give a better driving experience.