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My 2014 Navigator now has 73,500 miles and is 3,500 miles past the drive train warranty coverage. It now has a nice knock coming from the engine and runs fine otherwise. The Ford dealership did a $150 diagnosis and told me that they would have to tear down the engine to determine the cause of the knock which would cost the same or more than an engine replacement. I am getting a second opinion. Of course the vehicle is 1,000 miles away from home (and me) with my wife and kids now wanting to come home from vacation. I am surprised by this development as my 2003 Expedition with the same 5.4L engine had 236,000 miles when I sold it and never had so much as a hiccup. It has had proper service and the last major service was transmission fluid flush at 50,000 miles. Here is a link to the knocking engine video:
From what I've read that knock could be the cam phasers. Pull valve covers, change get the phasers, done. If that's it..no need for a new engine. Good for you for getting a second opinion.
My wife took the Navigator to Eagle Automotive Service in Littleton, CO based upon a recommendation. The service tech determined that the knocking was coming from the right side valve cover. I asked him about the possibility of the knock being cause by the phaser and he said the knock appeared to be coming from the valve cover and not the timing chain cover which would eliminate the phaser being the culprit. After removing the valve cover he discovered a broken rocker arm and scored cam. He is replacing all 12 rocker arms and the cam. The Ford dealership was a disappointment and $150 mistake.
Upon further inspection it was discovered that the engine had a broken valve stem as well. The repair now includes the head and valve assembly for the right side of the engine.
Time consuming and costly but still not a complete engine replacement cost - yet.
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