Hello all, We have a 2004 F150 FX4 with 3V 5.4L. It has had a tick (cam phaser noise) ever since we bought the truck. (When the truck was under warranty the dealer just said it was normal and not to worry about it, however another dealer wanted to put a new engine in it after the warranty expired...go figure). Anyway, a few weeks ago it started making another noise. At first it was just a rattle for a few seconds after startup, but now it is a fairly continuous rattle. We were thinking that it is a timing chain tensioner or guide. Does this sound like what is wrong? Here is a video of the noise it makes, most noticeable around 0:35.
Here is the list I had put together:
2- Dorman 917-250 Cam Phasers
1- Cloyes 9-0391SB Multi-Piece Timing Kit
inc: 2 timing chains, crank sprocket, 2 guides, 2 tensioner
1- timing cover gasket
2- valve cover gaskets
Is this everything I need?

The truck has 180,000mi on it and based on past experience, the life of a timing chain is about 200k mi (85 mercury cougar 302 slipped a timing chain at 208k, 88 f150 302 did the same shortly before 200k, and my 97 f150 4.2L broke a tensioner at 186k)
Thanks
-Brad

 

From what I've read the dorman cam phasers are no good and will fail again. As for the noise yeah I'd say its the timing chain.

 

i would say sounds like the chain has lost tension too. not sure if thats all the parts youll need but sounds about right. maybe ask in the modular engine forum also.

 

I am going to link another thread I found on the site when doing some research on the problem. My sound is the same, and I think at least in part it may be the Cam Phasers. I screwed up and put too heavy and oil in before a trip and it sounds like that was my diagnosis at least. I also agree with the other poster that perhaps the chain tensioner is shot, as I am l thinking that might be the harder slapping/ticking from the prior grindy rumbling I had for a while.

Here is a greatl link from the 150 forum- where I am going to ask a few questions
https://www.ford-trucks.com/forums/797525-diy-cam-phaser-replacement.html



here is a great U tube link some pro did for the phaser

 

OK so I ordered those parts as well as plugs, and an oil filter. I started on a Friday and had a couple finishing touches I had to do on the following Monday so it could have been a 3 day job if I worked a bit more on the first 3 days. I opened the engine to discover a destroyed chain guide and the hydraulic chain tensioner damaged but the phasers had no obvious damage. A couple things I discovered:the job was made easier by removing the battery box (it is only 4 bolts and unhooking a vacuum reservoir) and removing the 2 nuts from the studs holding the A/C Expansion Valve so you can move it far enough to remove/reinstall the passenger side valve cover without evacuating the system (Others have noted it was possible) It is a Pain the rear but easier then the alternative. When it comes to removing and then later torquing the cam phaser bolts, I tried the vice grips on the un-machined part of the cam behind the phaser but couldn't get a good enough grip, so I went around the body of the cam phaser itself with a pair of chain vice grips (It did nick them up a little but I couldn't hold them any other way). I also did the work without removing cam followers as I could't find a tool to compress the valve springs, The ford dealer very sternly told me NO when I asked if I could buy one. I ended up having to remove the oil pan far enough to remove all the hunks of chain guide from it so an oil pan gasket was also purchased.

I replaced the spark plugs while I had it opened up, piece of cake since they were anit-seized when they were put in. I also changed the oil and coolant (since they were drained), The plastic clip on the drivers PCV fitting was corroded on (yea corroded on) and broke instead of coming off so I will have to replace that.

After everything was put back together (I followed the haynes repair manual and the guide found here The Final Repair Guide to 5.4 Cam Phaser Tick/Knock Sound - Ford F150 Forum - Community of Ford Truck Fans I used the pedal to the floor no start for a few seconds to prime the oil pump then started the truck. Started easily and idled smooth and QUIET (no more funny noises other than the injectors) drove it all day then when pulling into the driveway it stalled. Upon a restarting it made a continuous knocking, and the check engine light came on, so I shut it off. After further research I pulled and cleaned the VCT solenoids (you can access these by removing a plastic plug from the valve cover and a torqx screw). The truck has been driven hundreds of miles over the last few weeks with only a system too lean code (I assume from that broken PCV fitting) and no other noises or issues.