I have a 2005 Ram 1500 with the 5.7 Hemi. I just installed the K&N 77 series filter on my truck and it really makes the truck come alive. The only problem is that when I accelerate it sounds like the valves are clattering. It only happens when I first push the pedal down a little, and stops after the rpms come up. Then after I reach cruising speed i can hear the clatter again from time to time. The rep at K&N said that the noise is common with the Hemi and I can hear it now more since the stock heat shield and cover were removed. He said that all Hemi's have this clatter and it will not hurt the motor. I went to the local Dodge dealer and they said there shouldn't be any clatter, but with the new air intake they were not sure. They of course said for $85.00 an hour they would take it ina nd do a few test to find out what the noise was. Before I go to the dealer and have them soak me is this a common thing with the Hemi's or not? Did anyone else have this problem and what did you do for it? I may just put my stock air cleaner back on the truck and return the K&N as the noise drives me crazy.
1. Yes I checked all the bolts and for metal rubbing, nothing.
2. Yes I sure it's the valves.
3. No I haven't changed anything else.

 

The PCM may need to adapt to the better airflow of the K&N.

 

Are you absolutely sure it's the valves and not the EGR? I have the K&N 77 and have distinctly heard the EGR valve fluttering since day one with it when accelerating. It's common and there is much written on it. The sound is always there, but hidden by the stock black plastic resonator that sat in front of the TB. It's REALLY echoed by the metal tube of the model 77. I'm used to it after 3 years with the model 77, but many hate the sound and have opted for the model 57 that has a plastic intake tube and therefore does not echo the sound nearly as much as the 77.
I'd bet that it's the EGR you are hearing and not the valves, as EVERYONE with a 77 reports this issue. There's a guy, I think in Texas or California who sells an EGR baffle specifically for use by people with the K&N 77. If it bothers you that much, return it and get the model 57 or let me know and I'll try to pull up the info on the guy that sells the baffle. Been a couple years since I've read anything from him, but I'm still on the forum the guy used to be on and could do a search...

 

I know this thread is quite old , however i just installed the 77 on my 1500 today and i was hearing the rattle. I did not do the research to see that people were reporting this prior to buying the 77 series intake. I just wanted to clarify a thing or two real fast.

The rattle if it is the EGR is not a damaging noise? Nothing that needs to be fixed? its just the flutter of that metal being echoed now ?

And two , do you or anyone happen to know anything about the guy that sells that EGR baffle or where to find one ? I am just curious. The noise really doesn't bother me, but if it does over time i would like to know a way to dampen it without having to change out my intake again.