2006 Explorer engine rattle
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2006 Explorer engine rattle
A customer brought a '06 Explorer with a 4.0 SOHC and 160K miles to our shop about a month ago. Problem was the dreaded rattling at startup which would eventually disappear within a minute or two, then it was fine until you shut it off and restarted it again after it had been sitting more than a few minutes. I started by replacing both tensioners but it didn't help. Borrowed the timing tools from the local Ford dealer, yanked the engine and replaced both cassettes along with all of the hydraulic lash adjusters. Tensioners and cassettes were genuine Ford parts, lash adjusters were Federal Mogul so everything was quality parts. Reassembled everything, it ran and sounded great. Three weeks and 1,000 miles later it suddenly started rattling again, sounds exactly the same as it did before. Customer is understandably upset and I'm at my wits end trying to understand what happened and why. Any ideas?
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