For the last 6 months, I've listened to a noise that would only be at startup and last for a couple of seconds. Today, I've been told that I need a new timing chain kit. This was an early 04 release that has been flawless to this point with 128,000 miles. Oh well stuff happens.
Further update, also replaced right cam phaser and when all work was done, no power. Mechanic tore the front end down 4 times and said, I don't know, I'm taking it to Ford. Ford tore it down again, could not find the issue. They called in the state support rep and he could offer no help and referred them to Ford engineering. Check the pressure which led to bad catalytic converter on the side with the cam phaser. I was able to see these. One was 1/3 melted and the other was cracked. I pull a 3500 # boat a couple of times on trips. No one has any idea, but it runs great now. No change in mileage, 18 average.
IMO, I think that someone did something wrong that changed the tining on that right side, took it for a test drive, and that melted the Cat. Nobody accepted blame. and the Local repair guy did not have to buy you a new cat. Sounds a little too convenient