Well bad day today. Yesterday truck was running great. Last night I drove 25 miles on the interstate at 75mph. No problems. This afternoon I go to start truck, as soon as it is running I notice an unusual noise. Pop open the hood and hear a knocking sound out of the right valve cover, towards the firewall.

I called my Ford dealer to see what the service dept. says. I was 30 miles from them, so I called a tow truck. I didn't want to do anymore damage by trying to drive it. So now just have to wait until Ford can look at it.

Truck is a 2001 F-250, V10 with 87611 miles. Does anyone have a clue to what happened? Lifter, pushrod, valve, valve spring? Just don't know from yesterday to today. I was supposed to leave for Grand Forks, ND. next week for 4-6 weeks for my job. Guess I'm glad it happened here, but possibly losing out on that job will hurt.

<a href="http://s1066.photobucket.com/user/IslandBlueV10/media/Autos/0317141747-00640x480_zpsadc61eeb.jpg.html" target="_blank"><img src="http://i1066.photobucket.com/albums/u420/IslandBlueV10/Autos/0317141747-00640x480_zpsadc61eeb.jpg" border="0" alt=" photo 0317141747-00640x480_zpsadc61eeb.jpg"/></a>

 

Given the year, are you sure it's not a loose spark plug?

 

I got a call today, dealer pulled the valve cover, said the valves are good but something with the valve cover itself is bad. Was quoted $661 to fix. I can't figure this one out. I'm on the road right now for work. I will be back in town Friday, I'll stop in and talk to them and find out exactly what is up.

I'm not sure how a loose sparkplug would sound, but this was a very clear knock sound. Like something hitting the valve cover. Just doesn't make sense.

 

A rocker cam follower probably jumped off. Expensive quote if that is what happened.

 

i am in the midst of the same thing here .. at least yours is in a truck body im working with a van .. just got the motor out an now to dive into it to find the noise

 

Okay went to the dealer. Here is what I found out. On the inside of the right valve cover their is a oil deflector where the crank case vent tube/pcv valve is, that keeps the oil from sloshing and getting sucked into the vent tube. The valve cover and this deflector are both a type of plastic. Anyways this deflector is attached to the valve cover by 2 small plastic pins and what to me looks like double sided foam tape. This deflector fell off and was being pushed around inside by the valves hence being knocked around.

There is no damage inside, but if left alone it would have been chewed up and gotten into the valves. They ordered a new valve cover. I think that $661 is a little expensive to replace a valve cover, but I have like 3 hours of diagnoses and pulling the valve cover. It is taking them 5 days just to get one, and hopefully will be here on Monday. I will ask for the valve cover and the deflector so I can post some pics. It surprises on what a poor design that is. Who would have ever thought that could happen. But at least it was something minor and I'll be leaving for my job either Monday night, or Tuesday morning.

 

Good Business.

 

Still don't have my truck back. Apparently the valve covers are no longer available. My dealer had to call all over to find one from another dealer. I even searched a couple places and could not find a right side. I could find the left side. Who ever thought a valve cover could cost so much problems!

 

And they still make the engine for medium duty trucks but cannot inventory them?

 

Has anyone searched eBay for a new or used one? Has to be someone somewhere with one or a 100 willing to sell 'em?

Good luck with this!

 

Interesting - no junk yards have V10s?

Problem here is the engines still being produced are 3-valves which use a different (aluminum) valve cover.

Glad your problem is "minor" - but gives me something to think about now... I've heard a similar noise once or twice in mine maybe...

 

I guess we'll all be a little more gentle changing out our pcv valves from here on out.

 

Okay finally got my truck back. $669 later. Like I said this is a poor design from Ford. I think they should pick up the tab, but that would never happen. Anyways here are the photo's:
<a href="http://s1066.photobucket.com/user/IslandBlueV10/media/Autos/HPIM0991640x479_zps0f65d77f.jpg.html" target="_blank"><img src="http://i1066.photobucket.com/albums/u420/IslandBlueV10/Autos/HPIM0991640x479_zps0f65d77f.jpg" border="0" alt=" photo HPIM0991640x479_zps0f65d77f.jpg"/></a>
This photo shows how it is supposed to look like. Notice in the upper right corner you see one plastic nipple this is the only thing besides some sealer holding this piece on.

<a href="http://s1066.photobucket.com/user/IslandBlueV10/media/Autos/HPIM0993640x473_zps6e870c46.jpg.html" target="_blank"><img src="http://i1066.photobucket.com/albums/u420/IslandBlueV10/Autos/HPIM0993640x473_zps6e870c46.jpg" border="0" alt=" photo HPIM0993640x473_zps6e870c46.jpg"/></a>
This one with the deflector off. The hole in the valve cover is where the PCV valve goes. You can also see where the plastic stud was in the upper right side off the PCV valve hole.

<a href="http://s1066.photobucket.com/user/IslandBlueV10/media/Autos/HPIM0995640x480_zpsa3895183.jpg.html" target="_blank"><img src="http://i1066.photobucket.com/albums/u420/IslandBlueV10/Autos/HPIM0995640x480_zpsa3895183.jpg" border="0" alt=" photo HPIM0995640x480_zpsa3895183.jpg"/></a>
This one showing the brown sealer.

<a href="http://s1066.photobucket.com/user/IslandBlueV10/media/Autos/HPIM0987640x479_zps89a8db7d.jpg.html" target="_blank"><img src="http://i1066.photobucket.com/albums/u420/IslandBlueV10/Autos/HPIM0987640x479_zps89a8db7d.jpg" border="0" alt=" photo HPIM0987640x479_zps89a8db7d.jpg"/></a>
This one without the deflector.

I hope this helps others. I am wondering if there is a way to reattach the deflector and save this for a spare. I am thinking maybe drilling some holes and using some small bolts and sealant.

I don't see any damage at all where it was getting knocked around. So it must have came off after my interstate drive, and the next day when I started my truck and heard the knocking.

My Ford dealer said this is the first one they have seen do this. They had to get the new valve cover from a Ford dealer in Burlington, Co. I did finally find one used one on e-bay today. I did search some more thinking of buying another one as a spare, and could not find any other right sides. I can find the left side. So like I said I am going to keep my old one for a spare. Again my truck only has 87611 miles. I plan on keeping this truck for as long as I can. If anyone finds a stash of new ones let us know. I would buy one. My new one was $199.99 so the other $469 was labor and diagnosis time.

 

tims01, Please keep me updated on your problem. I'm interested in finding out what your problem turns out to be.

 

You dodged a bullet there.

Poor design indeed. If that ever happens on any I have I'll probably just put a couple small SS bolts through (washer and nyloc nut) with some sealant and peen the end of the bolt over. That little plastic tit is pathetic.