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I have a 97 Ford Explorer Sport with the 4.0L SOHC. I somehow missed the notification about the cam chain guide and tensioner weaknesses. So, I havent had the plastic guides replaced yet. A few weeks ago the metallic rattling started up, so I took it into the shop. No surprise, it's one of the chains. I'm still waiting to find out if its covered under the warranty. The truck has 73,000 miles on it-- so I'm just over the 72,000 mile warranty for the tensioners.
What was more shocking is that the Ford service guys are saying I need to replace my entire engine because of sludge buildup! I know I've never gone more than 4000 miles without an oil change. I'm confused as to how it could happen to a well maintained engine?
Is there any chance that the failing timing chain / plastic guides could have contributed to the engine sludge problem?
I guess little bits of plastic could cause problems... I wonder if they were clogging up the filter?
what kind of oil did you use?
seems to me that the "sludge" would have to be extremely bad to require the engine to be replaced - ususally you can just start changing the oil more often and most of it will clear out, especially if the engine is still running OK.
hmmmm that's weird. If you've changed the oil regularly, there shouldn't be any buildup...unless you always changed it cold. That's the only possibility I can think of. I can't see how a chain would cause a sludge problem, although the plastic guides may have left chips in the oil if they came apart...?
Any strange noises other than the chain?
I'd have someone else pull the pan off and see if there's any sludge in it. I think the Ford guys may be pulling your leg, but not seeing/listening to the truck, I don't know for sure.
Well, I saw the truck last night and the engine is definitely full of sticky tar-like sludge-- they had the top of the engine pulled apart. It looks pretty bad to me, but I don't have much of a frame of reference.
I was hearing two noises. One noise was a loud metallic rattling-- the chain. The other noise was a ticking at startup-- like the engine wasn't getting enough oil. My pressure seems okay, but the ticking really worried me.
I spent yesterday hunting down everywhere I've had my oil changed over the last couple of years to prove I've truly maintained the engine. I actually managed to find all of them! I usually got my oil changed at PepBoys (Proline) or Jiffy Lube (Pennzoil). The engine would have always been hot from the drive. I was never too particular about what oil they used.
Im still pretty confused because EVERYBODY says this shouldn't happen unless I didnt maintain the engine... I guess we'll see what Ford says now...
Ticking at startup could be considered normal, as long as it goes away after a couple of seconds. There is very little oil in the top of the engine when you start it...that's why they put additives in the oil...one additive actually makes a very thin layer of oil "stick" to the metal.
Yes the sticky tar-like (?) sludge IS strange...never heard of that happening in an engine that's seen regular maintenance.
I do know that Toyota had a sludge problem with their Camry V6s. The oil was sludging up around the cylinder head drain back passages, so the oil couldn't make it back to the oil pan. This caused problems with the valve seals and the PCV system, resulting in oil consumption. You can see the oil sludge if you pull the valve cover a lot better than from the bottom.
I have never heard about this with a Ford engine. If it's there, I guess I can't dispute it. I don't know the proper path to fix the problem, but it seems a new engine is quite severe. I think Toyota was recommending switching to synthetic and changing the oil at a shorter interval (if the problem isn't too severe).
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