I have the above. It has 54,000 miles on the engine. I have noisy lifters and an engine knock right bank. The nenine has never been taxed when I have owned it. I bought it with 30,000 miles and the kknock and noisy lifters was there but very light. it is now more noticable. The knock is loudest on cold start but even though it is quieter after oill gets around it is still there. They have changed #6 injector saying that was the problem. If anything this seemed to make the knock more noticable. Possibly it got rid of some other noise
They now say the cam phase unit needs to be replace. Anyone else have this trouble. If so what cleaned it up? I think I have either a weak oil pump or a rod knocking. What do you think?
I've found that the 5.4l engine is pretty noisy even when everything is working properly. That being said, the 2004 5.4l is probably the noisiest of all the model years. But at least it doesn't have the sticking fuel injectors of the 05-06's which can hang open hydro locking those engines. The cam phaser noise is also well documented especially in the 04's and can sound a little like a rod knock but higher up in the engine. Also be sure to use at least the motorcraft oil filters. After market filters have been know to make the 5.4l engine knock as well.
From my questioning of Ford personnel, I have found that the Cam Phasers typically are the problem with noise (unless your engine is like mine and decides to drop a valve into the cylinder). From what I understand, the Cam Phasers rely on oil pressure to advance the cam and a spring to retard the cam.
As they wear out, they bottom out on the stop, which causes the ticking noise.
Again, this is what I was told by a Ford Service Manager, so don't hold me to it. I do not have any info on a cost to replace the Cam Phasers, but I understand it isn't a cheap fix.
As ford9c stated, if you do not have a Motorcraft filter on the truck try that first. It has been stated on this forum that the cause of the "knocking" upon startup in these new engines sometimes can be attributed to oil filters with incorrect or defective antidrainback valves.
I had my cam phase sensors changed under warranty. The "knocking " noise is usually only heard after the oil has warmed up... see if you meet the criteria in the TSB 06-4-7. If you do a search on this forum, you should be able to find a post or two containing the TSB. Hopefully, someone will see this and post the TSB.
My 04 Screw 5.4L 3-valve is noisy as well. However, I found the solution for the most part, and I whole-heartedly agree with these guys. A Motorcraft oil filter is CRUCIAL to these engines, or any other Ford for that matter because of the anti-drain back valve. I use nothing but Motorcraft on all my Fords for this reason. Aftermarket filters are cheap and sometimes made of even cardboard!! (Try taking an aftermarket one apart sometime and you'll be surprised). My other vehicle is a ZX2 escort which other people's I have heard get quite noisy, but mine is as quiet as can be, and I attribute that to me using Motorcraft oil filters all its life...and it has almost 101k on it now.
Anyway...getting back to my point...I bought my 2004 Screw used...and when I did...it had aftermarket filter and oil in it....the wrong weight I am guessing. This can cause the knocking noise bigtime. My suggestion would be....try changing to a Motorcraft oil filter...and using actual Motorcraft 5W-20 motor oil (you can buy it at WalMart quite cheap). As soon as I did this...my engine quieted down quite significantly....and it seems to have almost solved my problem completely! I would try this 1st. I am going to now use Motorcraft oil filters AND oil for the rest of this trucks life. The 5.4L seems to be very picky about what it uses.
I know i am probably opening a old wound on on this but my 04 screw has the low idle tap to it but when you get around 1100 to 1300 RPM that tap gets louder but them goes away from what i can tell. I have listened to it and it sounds like a injector on the drivers side but can't quite tell. any other suggetions on what it could be or ways to narrow it down on what it is.
I can tell you mine has been making this noise since brand new. Sounds like a diesel expecially in drive throughs. I now have 49,000 miles on it and its still making the noise and still runs great, just my 2 cents.. So i guess i wouldnt be to worried.
dptho, yeah i have the same exact truck and it sounds like a diesel. ive learned from the other guys on here that its the cam phasers but it wouldnt hurt anything unless it gets real loud. i like it so no use spending money to fix it...unless it really is harmful