I started getting a ticking noise at first then a knock and after some trouble shooting I determined the timing chain needed service, sure enough the timing guides were broken and the tensioner guides were worn almost through. Since I was missing large chunks of the guides it was necessary to drop the pan and clean it out, good thing too, the pick up tube was nearly clogged with bits of the broken guides. I inspected everything while I was down there, The rod bearings seemed ok, no play or noticeable damage and same with the crankshaft, nothing that was obvious, no metal particles that you would expect from a spun bearing. Oil pressure is good and no engine codes being thrown. After reassembly the engine starts easily and runs smoothly except it knocks horribly on start up then quiets down. under load at about 2000 rpm it starts knocking again. I need some ideas on where to start looking. I double checked to make sure the timing chain, crankshaft, and cam marks all lined up before reassembly but is it possible the chain slipped a notch? Could there be bits of the old guides clogging up the oil ports or is there something else I'm missing here?

2003 Explorer, Eddie Bauer, 4.6L SOHC. AWD.

 

How many miles are on it?

 

180K, but it no longer matters, got tired of messing with it and sold it for parts...