2006 F-150 5.4 3V
Making this noise.

Ran fine for 150 miles on remanufactured engine from Powertrain just fine, then this started on every cold start but It went away totally last night and the engine ran smooth and strong. Started it this morning and is making that noise again. Hoping its an easy fix on my end. Any advice? Oil level and pressure good. 5w20. Help please.

 

Appears it's in perfect harmony with the passing of the print on the serpentine belt.

 

It's so hard to tell thru a mic and then a speaker....at first I kinda thought chain rattle but I'd expect that to pretty much go away with a little RPM unless your tensioner is really FUBAR. Could be phaser clack.

See if this helps you and let us know what you find!

 

Ok, so this morning, upon cold start the engine made a very rare rattle or clack and then went quiet after 2 minutes or so. This New Remanufactured Engine is really Awesome when running smooth which is 95% of the time so far. The actual new milage is 320 .00 now and it is purring like a kitten at idle and is spunky at takeoff but I have not gone above 70mph yet. So, some facts to fill you in.

Engine swap at 169,661.00 due to low oil pressure. Cam shafts and towers were scored too deep to do a time job as that's how I approached this at first.
Dropped in new engine from Powertrain for about $4,400.00 and had my transmission rebuilt and beefed up for $2,700.00. It all was worn out as you would expect pulling a boat and camper for 15 years or so.

I just found a notice from Powertrain stating that some f150s and a few more models will expriance an intermittent rattle upon start up, ect. I have already contacted them and am awaiting a response. Will post pic. So, check out this morning's start up an let me know what you think. Really hope this helps some one! Waiting for my YouTube to upload. Thanks to all who replied. I am not sure about this just yet.
How does this sound?

 

Yes I did notice that too. It is still doing it this am as usual and does not completely go away until the engine is totally warm. Stumped.

 

So, you've tried without belt?

We did a timing set on a 2V 4.6. On first start there was a weird knock. Took belt off, gone.

Determined most likely alternator. About a year later the truck is melting and shredding belts. Found rear alternator bearing toasted.

 

Is there not a warranty on a Powertrain reman?

 

Hello all. As I am new here it took me a bit to navigate the thread, so bear with me please.

This new remanufactured engine from powertrain now has about 400 miles on it. It is under warrantee for like 110 hour of labor, and a no fault clause I paid extra for to the best of my knowledge.
The sound sounded even worse this morning but again totally went away after about 5-10 minutes. The engine temp gauge was still a tad on the cool side. There is no way I would drive it like that until the sound goes away, and it does every time. I drove to work and it ran perfect. mixed city driving and the interstate for 11 minutes at 70 mph, then more city stuff. I will change the oil at 500 miles per instructions.

It is hard to pinpoint and nothing on utube sounds like it that I can find. Before I take it in I want to remove the serpentine belt and cold start it. That should tell me if it internal or external right??
The sound resonates all over but my ears keep coming back to the top drivers side valve cover. If its Powertrains issue I would assume they would cover it but if its say the AC clutch or anything else it will be on me.
Sounds like the drivers side phaser to me. A skipping, clicking, taping noise. Metal on metal somewhere.

I will post a video of the removal test for all if it helps. This is all I can think do do.
Good Day.

 

You'd be able to observe the a/c clutch engaging and disengaging and you should be able to unplug it. Without power it shouldn't be able to engage the magnet

Let us know what happens with no belt! Obviously you don't want to run long with no water pump but at least your symptoms seem consistent every morning so you should know right away.

 

ABSOLUTLEY! This will be the big test. I plan on this being my last truck in life almost 60 now so this is it. How did I get so lucky, the 5.4 3v.

 

Sorry, had to chuckle at that. 59 is mighty early to be thinking ANYTHING is the last one you buy. I'm 76 and its still not safe for me to see something I really want.
On the 'noise', I'm just hearing engine noises. Shut the hood and get in the cab and close the doors and windows. Is it a problem now? How about with the hood shut, from 12' away - is it a problem?

 

Ahh, some words of wisdom from an elder! Respect to to you sir. lol. BUT.. It surly is a problem I feel certain of that. The belt is off now. Home after work. I looked for the obvious an nothing except a small amount of belt debris around the alternator. Rubber bits. This came from the fact that I did not tighten the two lower alternator bolts all the way tight after install. I torqued the top bracket bolts but it got late and it slipped buy me. I found them lose after checking for this problem. It made no difference however the belt does squeal on start up now. It did not the first 300 miles or so. one question please...

The clutch fan. Now that the belt is off, when I hold the the water pump pulley with my hand I can still turn the fan endlessly, either way. Is this normal. I thought I read 4-5 turns max or it was bad. The clutch fan is original.

 

That's how I would expect a new engine to sound at start up and that's how it sounds when running at idle just a little slower. I had to get ready for work and was rushed for time.
This caused much anxiety but I do feel better now as far as the new Powertrain engine install goes. The water pump is new. The alternator was rebuilt locally along with the starter prior to install. The new belt show's signs of wear too early in the game and I do think this is due to the lower two alternator bolts being lose by 1/8 inch or so and running it like that for 50 miles or so before I found and tightened. However the top alternator bracket was in place and torqued to spec all along. Just info.

So, the AC, the fan clutch, power steering pump what else? I did note APP 3/8 end play in the power steering pump pulley but steering is fine. Any thoughts any body?

Hey I just noticed in the first video you can see the lose alternator bolts!

 

Team TFI thought held a contest for most convoluted belt routing on the modulars and who could squeeze in the most idlers. The design from the guy who won are what you see.

How are your idlers?

 

New with install. I did just learn from fordmaculoco vid that that steering pump end play is normal also so I think I can rule that out.
That clicking sound sounds so much like the AC clutch but thats on the other side and low to where I think I hear the noise. However as someone said here just unplug the AC and see so I will try that.