Hello all,
I have a 2004 F150 with 195,000mi. For the last several moths the truck has had a rattle on startup, some days it is barely noticable and only on cold starts, other days it is loud and occurs on every startup. The truck was most recently serviced at the Ford dealer and is filled with Motorcraft 5w-20 syn blend and Motorcraft filter Every change before was either Motorcraft syn blend or Penzoil Platinum (I have always used Motorcraft filters on it) and the noise continued after oil changes so I don't think the drain back valve is the issue. I replaced the cam phasers, timing chains, chain tensioners, and guides about 15,000 miles (2 years) ago and the vct solenoids shortly after that. Here is an audio clip of the noise (I know the truck also has an exhaust manifold leak, I plan on replacing the manifold while im working on it)


Is this noise the lash adjusters or have the cam phasers failed again (they were dorman parts)? If it is the lash adjusters, can they be replaced without removing the cams? will failed adjusters be obviously damaged? Should I also replace the cam followers? do i need to replace all 24 at once or can i safely replace only damaged ones or maybe just 1 bank (noise seems to only be coming from the pass side)? thanks
-Brad

 

It's definitely rattling but you notice it only lasts for one or two seconds. I'm a 'snake oil' guy, so I'd probably try an additive or perhaps Castrol GTX Magnatec.


GTX MAGNATEC Synthetic Engine Oil | Motor Oil | Castrol USA

 

Try amsoil, full synthetic, first 5 w 30 !!

 

You mentioned an exhaust leak.
To me it sounds like an exhaust leak.
If that doesn't fix it, I would pull the lifters. You do not need to pull the cams - there is a thread near by that discusses it
edit: here it is https://www.ford-trucks.com/forums/1...placement.html


Previously I saw a youtube video that showed how to change the lifters (without removing the cam).


After fixing the exhaust, I personally would replace lifters before phasers and timing components.

 

I planned on fixing the exhaust leak at the same time. The noise is a lot louder in person I can't seem to get my phone to pickup the noise without it being drowned out by the exhaust leak. The phasers, chain, and tensioners only have about 15,000 miles on them so I hope I don't have to replace them again.

I know exhaust manifold leaks are common on these trucks, does the manifold usually need replaced or do you think I can get by with gaskets and new hardware? Thanks
-Brad

 

I'd bet on an exhaust leak. Just my thoughts.

Good luck.

 

Exhaust man. Gasket. Pull cab or motor? Some studs are rusted off. Pass. Side. Should I do both sides?

 

Could be the tensioners bleeding down, hopefully not though. Try a few different brands of oil. Different additives seem to quiet engines. My truck always had an initial start up rattle with Motorcraft oil.

 

It's an exhaust leak. Stud rusted off. The whole set up is trash. Bad engineering ...

 

Would you mind starting your own thread? thanks


I don't think it is, the noise is completely different than the one it made when the tensioners failed last time, it is a lot more pronounced. Since the rattle started I have tried:
Motorcraft Synthetic Blend, Penzoil Platinum Full Synthetic, and Quaker State Full Synthetic. Noise occurs with all of them. I am a little leery about using oil additives, these engines already have top end oiling issues I wouldn't think thickening the oil would help. This week I have started noticing a high pitched tick/chirp at high RPM, don't know if it is related but it makes me wan't to pull it apart and look at things quicker, unfortunately my 97 just dropped it's fuel tank again (Rust has hit this truck real hard) so I have to keep the 04 together to drive. Exhaust Manifolds and studs are on order and should be in on Wednesday once I get them replaced I hope I can get a better recording of the rattle, No if only my truck fit in the garage.

 

Stupid phone. Need to move to other thread.

 

Yep....first thing that came to my mind too. Definitely and exhaust leak