I have a 2004 Mountaineer, awd, convienence group, with 7000 miles and a front end rattle. The dealer's service department said I need a new cat. converter. Is this common or a sign of things to come, or do I need one because Ford is paying for it since it is covered?

I do not believe that the dealer would just recommend replacement just to put it on.The reason i say this is they have to ship all high dollar parts back to ford motor company for warranty inspection and if ford determines that the part is not defective they may charge the dealer back and make them pay for the repair that was not needed. Also in the 90's forddid have some problems with cat convertors so it is possible.The 2004 mountaineer is a very solid vehicle and i do not believe this is a sign of things to come...