Good evening everyone, I would like to see if anyone else has experienced this issue. (First I have been a loyal Ford customer for years) Recently purchased a 2004 Supercrew 5.4 3V. This truck was purchased because the 2002 Supercrew with 20k miles apparently had an issue that two different dealers said they could not resolve and I would have to drive it until they were able to get a fix from Ford.
This was the second time I have had no so good luck with Ford's F150. I Purchased a 99 with the 5.4 that had the piston slap issue and had to have the engine replaced twice with less that 10K on it and then the transmission failed probably from the engine installations and something not being installed properly. Ford did the right thing and stepped in to help get me out of this truck into a 2000 F150 and had no substantial issues with that one.
Back to the 2004, I have had to get the Continental tires rebalanced for vibration issues and have experienced the rear doors not opening from the inside. Both issues resolved.
The truck has now developed a tapping noise coming from the right side of the engine. Sounds like an older engine when a lifter does not pump up all the way. The engine has 3500 miles on it. The Ford dealer first told me yesterday that it was an issue called Piston Scuff (same issue that the 99 5.4 litre had called piston slap) and that they were going to have to replace the engine (I thought here we go again) Today they called me and said that the issue was with the Cam Phase Sensor. They said that this is an issue that Ford is aware of and they have a tentative data of March for a released re-engineered Cam Phase Sensor to correct this noise. They said that there is an internal TSB for this issue but I have not been able to find or be shown this.
Just getting a little frustrated with the quality I guess. I am trying to keep a positive attitude about the whole thing but I hate driving a new truck that sounds like it has a bad lifter. I jokingly explained to the service manager that if I wanted a truck that sounded like this I would have bought something like a worn out 72 Dodge. (Hope I do not affend anyone with that, sorry if I did)

So has anyone else experienced the issue with the Cam Phase Sensor?

 

I too have the same problem with 3000 miles on 2004 5.4 .The tapping is not there at start up .After warm up at idle under 1000rpm the tapping can be heard .The dealer replaced the sensor and the tapping is there with the new sensor in place.Although not as loud as before it is still noticable.I was told that it is a crap shoot if you get a good one or not.I was glad to see your mention of a re-engineering to the sensor by March. I was at the dealer today and they were not aware of a new developement for the cam sensor. We did feel that one would be in the works as this dealer has replaced more than a few and some more than once .I will be going into town this weekend and I will advise him of your information.

 

I too have had this problem and the dealer replace the valve sprockets (no help) and then the torque converter flex plate (don't ask me why) but with those changed it still is like that and they told me I will have to live with it. I am at the point of filling a lemon arbitration hearing.

It started at about 1100 miles and has gotten worse no matter what they try. I now have 5500 miles and I can hear it inside the cab with the radio off and the windows up.

 

So what did they say? The sensor is hitting the sprocket? Doesn't make any sense, unless physical contact is made.

 

They said the service report required the valve sprockets to be changed.

I think Ford knows they have a real problem and they are trying to hide it.

 

Thanks for responding, The dealer said that they did not want to install the kit that is available at this time because it more than like would not resolve the issue. They said that they spoke with the Ford Hot Line\engineers and were told about the new kit\service part to be released at the end of Feb beginning of Mar. I really hope this is true.
Treefarmer:On mine the noise starts up at start up and continues but it may actually get a bit louder after it warms up.
JBOW34: Mine is exactly what you described as far as inside the cab with the windows up etc...
I would like to see exactly what this part looks like. I was under the impression that it was kind of like a magnetic pick up type of sensor and was trying to get the service advisor to explain but he could not.
I would be nice if someone here might have a diagram or description of how exactly this Cam Phase Sensor works.
Thanks again for the replies

 

but if you think that's bad, today after 2 years of service visits i finally got my bmw fixed. 39k miles and the camshaft position sensor went. I had taken it in 6 times before for a knocking sound on startup, sounded like a diesel peugeot. Anyways they found the problem 13 bad lifters, i was expecting 1,2 even 3 but not 13. i guess the moral is it can be a bmw or a ford, any car will have problems. hopefully they fix em.