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I have an 2004 Expedition XLT with the 5.4ltr. Only in the morning when it is started it makes an unnerving knocking noise, but goes away as soon as the motor heat up to operating temp.
The noise sounds like a start of a rod knock but goes away. It is loud enough to hear at first and after about 2 to 3 minutes it goes away.
Any ideas what that might be??????
I thought it might be the air compressor but I would think it would do it every time the compressor comes on.
Piston slap is extremely common on the 5.4 when cold. Rod knock gets worse as the engine warms and clearances tighten. There also can be an issue with timing chain tensioners making noise. I had a 99 F150 with 265k miles on it, made awful noises when cold but was quiet when warm and still ran like a champ. I quit worrying about the similar noise in my 145k mile Expy after that. It is normal, strange and off putting but normal.
Piston slap doesn't sound like something I want to ignore. But I think you are right, I have listen to one other expedition and two F-150's all with the same sound.
Thanks,
mike
It isn't as bad as it sounds, and it definately isn't a terminal condition for the engine.
We were ready to replace that high milage F150 but it ran so good still you couldn't justify it. I would get on it good in the mornings when it was cold and rattling, I drove it hard up mountain passes, it never got any worse during the 15k miles I put on it, never broke down and only used about a qt of oil between 5000 mile changes.
I try to let my Expy run a couple of minutes until it is quiet, but I am also convinced that even though it sounds bad, it is going to run good for years to come.
The slap is a result of Fords attempts at lowering internal friction by running shorter skirt pistons.
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