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My wifes 2008 Explorer Eddie Bauer edition has the 4.0 V-6 engine and we have a similar noise to what CA stated up above in post 53. The engine is quiet when we start it up but when we give it gas, we notice the noise that sounds like marbles in a metal coffee can being shaken. The noise is only present between 2000-3000 rpms. The noise is more noticeable when giving it gas at more rpms when the engine is cold but after the engine warms up, it seems to completely disappear sometimes. Most of the time it likes that 2500-3000 rpm range to have the noise when under light throttle, even under a load going up a hill.
Does this sound something like what a guide / tensioner issues would be? From what I have read up on, it is primarily noisy when it first starts up and at idle which ours does not do. Our car now has 106,000 miles on it and of course is out of warranty. We are taking it tomorrow on a long trip and I'd like to have a piece of mind that the engine isn't going to give out on us a long ways away from home.
On a side note, the top plastic tank on the radiator I noticed is starting to crack outward. Almost like there is too much pressure inside the radiator. The cracks are straight across where the reinforcing ribbing is too, in two spots. (one spot on each reinforcing rib in the center of the rad.)
Also, is there a way to tell if it could be the internal part of a catalytic converter rattling vs. the timing chain tensioners?
I know this is an old thread, but... click here for a detailed write up
on changing the Left+Right OilPressurized TimingTensioners in the
1997~2011 Ford V6~4.0L~SOHC Engine as part of a 75k~100kMile PreventativeMaintenance routine;
the original weak design of these Tensioners is a root cause of TimingGuide failures in many early SOHC engines.
I know this is an old thread, but... click here for a detailed write up
on changing the Left+Right OilPressurized TimingTensioners in the
1997~2011 Ford V6~4.0L~SOHC Engine as part of a 75k~100kMile PreventativeMaintenance routine;
the original weak design of these Tensioners is a root cause of TimingGuide failures in many early SOHC engines.
Yes it certainly is an old thread but I just now found it and will read all 13 pages tomorrow!
I've had year 2000 Explorer with 4.0 since new and it has just over 272,000 miles now and still original timing chains, guides etc. and no tensioner or chain rattle except at startup, but only after the truck has sat unused couple of weeks there is a slight rattle that goes away in about 1 second.
I used the truck for business driving for many years and it always had lot of long highway trips during those days, but lately it's just occasional driving as a spare vehicle.
There has been no short trip city driving.
The truck is in excellent condition considering the mileage, but the clear-coat paint is starting to fade on the roof & hood and some suspension parts, like shocks will need attention soon (all original still).
The engine oil was always changed at 5000 miles interval during those days, but now it's every 3000 miles - I've always used 5W-30 conventional oil but switched to 10W-30 last week due to the 1 second rattle at startup - time will tell if 10W-30 will help that?
I know it's on borrowed time but I don't think the truck owes me anything after 272,000 miles!
I will give updates later in case someone is interested.
PS. The Explorer 4.0 timing chain tensioner recall (00M12) was done in July 2003 when the truck had about 31,000 miles on!
I just bought a 2006 Mercury Mountaineer (Similar to the Explorer) with a 4.0 Guy said his wife was driving it and it quit. Towed to a shop where it was "diagnosed" as timing chain issues. Might not have bought it if I read this thread before. But, a lot of good info here.
Had to read this topic since I replaced the complete timing system in my '04 Ranger SC 4x4 last summer, not because I had a problem or due to noise but due to all the internet hype about what might happen.
Bought my Ranger from the Ford dealer who sold new to original owner in Oct 2003, he put 2,037mi on it before trading it back and asked them to find him a 'yota Tacoma. I got the benefit of 10mos depreciation (owner left sales receipt in glove box - he paid just over $25k) and drove it home for $19k early July 2004. Has been a great truck, trouble free from the start, first tank of fuel averaged 19.8mpg and that with factory tow package and 4.10s. My driving is better than 97% highway and that's 65+, I believe the 5R55E has a lot to do with the economy. I don't baby it, never have, and take it WOT regularly. I have hauled our 20' aluminum boat (4,000lbs rolling weight on the trailer) close to 15k mi back and forth to our favorite fishing spot, OD always off when towing or hauling a heavy load.
Fast forward 20yrs, filled it up yesterday and fuel economy was 19.2mpg. Nothing but routine service during my ownership, oil & filter every 3k at the local shop because I know everyone there and don't like fooling with oil disposal. Thought they were still using non-synthetic oil but learned they switched to synthetic blend 5yrs ago, had I known that I'd have extended oil changes to 5k which is what I'm doing now.
Brings me to the decision to pull the engine last summer with 133k on the odometer and do the timing system as preventive maintenance. Lots of folks told me I'd never get it to run right again, even the guy at the local shop said that and I've known him 33yrs. Undaunted I pressed forward as I never back down from a challenge. I plan well ahead, rehearse the process, buy geniune Ford parts, and have the knowledge and skill to do the work. I give kudos to Ford tech Makuloco for a thoroughly detailed process on his 'tube site, really like his no BS approach.
When I pulled the intake off the valley was spotless, same thing when the valve covers came off, looked new inside, heck, even the water pump which was same as when it left Ford, looked new on the inside. I was stunned!
Other than some parts delays due to improperly packaged parts (LH thread cam bolt in a sealed package labeled as RH thread bolt) and a few other small bumps along the way, the replacement went without a hitch. There were some curse words for engineers with their head where the sun doesn't shine, accessing torque converter nuts was a big one, and a few others that require patience and perseverence but they all got taken care of.
And my buddy at the local shop who said it won't run right again, he didn't say a word when I dropped it off for him to recharge the AC.
Did I need to do it? No, turns out mine was built with the updated components (Aug '03 build date) and there was no evidence of any wear or pending failure. IIRC, there was one last update in '06 or '07, so the parts I installed were "latest greatest". Mine also did not have a balance shaft that, supposedly, "all 4x4s" got.
Engine's good for another 100k, the 5R55E still shifts nicely thanks to fluid/filter changes every 50k but the 8.8 is getting a little sloppy, maybe it's time I learn to do one of those since I've got the tools. Thought I'd share a success story with one that was built right from the beginning.
Yes it certainly is an old thread but I just now found it and will read all 13 pages tomorrow!
I've had year 2000 Explorer with 4.0 since new and it has just over 272,000 miles now and still original timing chains, guides etc. and no tensioner or chain rattle except at startup, but only after the truck has sat unused couple of weeks there is a slight rattle that goes away in about 1 second.
I used the truck for business driving for many years and it always had lot of long highway trips during those days, but lately it's just occasional driving as a spare vehicle.
There has been no short trip city driving.
The truck is in excellent condition considering the mileage, but the clear-coat paint is starting to fade on the roof & hood and some suspension parts, like shocks will need attention soon (all original still).
The engine oil was always changed at 5000 miles interval during those days, but now it's every 3000 miles - I've always used 5W-30 conventional oil but switched to 10W-30 last week due to the 1 second rattle at startup - time will tell if 10W-30 will help that?
I know it's on borrowed time but I don't think the truck owes me anything after 272,000 miles!
I will give updates later in case someone is interested.
PS. The Explorer 4.0 timing chain tensioner recall (00M12) was done in July 2003 when the truck had about 31,000 miles on!
Update:
I've only put couple of hundred miles on the 2000 Explorer since switching to 10W-30 engine oil, but I am glad to report there was no timing chain rattle at all during a first startup after it had been parked & unused for about four weeks!
5W-30 engine oil may be better for gas mileage, but mpg does not matter in this case since after 23 years / 272,000+ mile of active use, the Explorer will now be in retirement mode as a family backup vehicle & will be used only occasionally as needed.
But, a lot of good info here. 
