I have 2004 Durango HEMI 4x4 and it has developed an exhaust type noise on the passenger side somewhere around the floorboard up to the dash area (that's where it sounds like it's coming from)

I took it to a muffler/mechanic shop and they put it on the lift and checked it and listened with a "stethascope" device.. They were unable to find the noise.. We took it for a drive and I didn't even hear it...

Here is when I hear it .. It does not seem like I hear it when it is cold... but I am hearing it all the time when it is warmed up and under load.. say in overdrive going up a hill .. When I press the gas down enough to put it under load but not make it shift .. I hear a noise that sounds like a I have a hole in the exhaust..

I replaced the EGR valve and the seal on the "tube" Still does the same noise...

Any ideas ? Does this model suffer from the broken manifold bolt problem?

I even changed the oil to a heaver weight thinking it may be valve train noise..

It's driving me nuts .. I can't hear it when I get on it (thanks to K&N CAI and Flowmaster )

 

I thionk the broken bolt is more 'common' with the 4.7 liter. The system does have a MDS system on it that will shut down 4 of the 8 cylinders under light load in order to gain MPG. It will kick on once you nail it ot overcome a car or hit a hill and will spike your RPM as all cylinders fire. Type in 'hemi tick' in the search function in the black bar at the top of the page to see more. It could also be the exhaust system hitting your floorboards and you could check that the hangers,
FF

 

I thought the 2004 did not have the MDS .. How can I tell if it is equipped with MDS? I never hear the tick noise ... maybe that is what it is ...

Anyway to disable the MDS ?

 

All 5.7 liter have the MDS system and the Diablo Sport Tuner can turn it off (As I was told by installer) or you can change out the lifters which would be costly:

http://www.allpar.com/mopar/new-mopar-hemi.html
FF

 

The Durango didn't have MDS until 2006 model year. The cars have always had it but the trucks didn't until '06

 

the 2004 durango is the only 2nd gen durango with the hemi that does not have the mds motor in it they added that in 2005 i own a 2004 and my friend owns a 2005 and he has it on his

 

Try to move a tissue around the manifold and see if it moves as this would indicate a leak or a broken bolt and I was wrong about the MDS on the 2004 (passenger cars had it only),
FF