02 E350 van, 5.4l with 130,000 miles. I bought this van out of state from a reputable dealer and didn't notice it tapping/knocking on the way home, but since i've had it 6-8k miles or so, i've gotten real familiar with this noise. My noise is not at startup as most are, but is completely random. Sometimes at startup, sometimes not, cold/hot doesn't matter either. The only time i can ALWAYS get it to do this is to drop it in reverse and back in to my driveway (or any back), so i know you're thinking it taps under load at low rpms, but it doesn't always do it going forwards! More often than not, i get the knock at low rpms and it goes away as rpms increase with acceleration. I have read maybe cam phasers? Would this be a possible problem with an 02 5.4? Also, I sometimes pull a 6500lb travel trailer. I guess i'm just looking for some piece of mind on whether this thing is going to blow up one day and if so, is it more than likely to do it under load? I'm getting a little paranoid towing with it because i know it's working pretty hard pulling that trailer.
The only other info i can give is that it doesn't use, leak, or burn oil. I'm running mobil1 5w-20 with the Ford oil filter.
I have NOT had a Ford mechanic look at it yet but i have a couple of good ones locally. I'm just trying to narrow down what the problem might be and whether not i should address it right away.

thx

 

I would check the flex plate when they crack they can tick like that..

 

I don't believe that engine has cam phazers the newer 3valve has them from I think 2004.Thanks for the tip Big pipes gonna check mine for that.

 

Tell me more. I'm not familiar with the flex plate but I'm about to search.
Thx

 

its the equivelant of a flywheel in an automatic trans vehicle, and no you dont have cam phasers. the flexplate bolts between the crank and the torque converter. they do crack from time to time and will tick or squeak.

 

Scotty I've had the cracked flex plate on two different vehicles and that noise can scare one half to death------the dollar signs flying out the window. I did a quick search on YouTube for cracked flex plate and found quite a few----maybe check it out to see if any of them are similar to yours?

Its not a tough job replacing one but it does involve R&I'ing the trans since it is the auto trans version of a flywheel as J.Grif said.

 

Thx guys, I hope I'm narrowing this down!

 

well i looked at some Youtube videos on the flex plate problem, i don't think this is it. My problem is much more subtle, a tick inside the block somewhere i think. I haven't tried a stethoscope or anything because mine hardly ever does it at idle, usually under light load or acceleration, and it goes away as rpms increase. I'm gonna take it to a good mechanic soon i guess, i don't think i could video or record it, it would be impossible to hear i think.
Anyway, it's not my daily driver so it hasn't become urgent yet.

 

Check your exhaust manifolds for broken manifold bolts. Common problem that will usually give a ticking sound when you accelorate and will get quiet a you ease up on the pedal. If there is more than one bolt broken it can sound similar to a knock or tap.

 

Scotty can you crawl underneath while someone gently accelerates the engine, perhaps getting the sound more isolated? This might also be done with the engine cover removed, listening and observing if the tick is internal or external to the engine.

 

Thanks, I'll try that today if I can find a helper.

 

I bought a 2002 E350 15 passenger van with the 5.4 and it had an exhaust leak that ticked very quietly I thought it was a lifter or something else. The Ford tech explained that in E series in 2002 had some exhaust manifold gasket issues.

 

Hmmmm. Thx! That's good to know. I'm gonna get under there later today with a good light and a stethoscope while the motors cold.