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I had no bites in the 4.2 forum, so I'll try here. Also have a few updates...
Here goes... My Alternator went on vacation about 2 weeks ago. Popped a new one in and all is good as far as that goes. I also changed out the DPFE sensor due to a P0401 code, and it cleared that up. Ever since that day, I have a ticking (sounds like lifters) sound that gets worse on acceleration. I've flushed out the engine and changed the oil... added a bottle of engine fixer-upper crap thinking it might just be sludge or something. Nothing seems to be doing the trick.
Well, thinking this might be a good excuse to change plugs and wires, I went ahead and did so. Engine is running a lot smoother, but the ticking is still there. It seems to be coming from the bottom right, possibly from the ex manifold. I've read several threads on here that refer to manifold bolt breakage issues, but I've had a look and can't see anything amiss.
Would it be worth my while to r&r the manifold in an attmpt to solve the problem? The bolts are rusted all to hell, and I'm afraid I might break one off. May be a good excuse to pop in a couple of headers at the same time. I could convince the wife that I "need" them.
hehe...jsut tell her they are the replacements and the originals are warped! You are headed in the right direction. Although, you could get a mechanics stethescope (sp)and pin point the ticking noise. Changing out an alternator or DPFE wouldn;t cause the ticking to start. Unless you wrenched on something wrong, but from the sounds of it I wouldn't think that either.
I tried the stethoscope and I can hear the ticking the worst in two places... on a bracket next to cylinder one that is mounted down by the manifold and on the manifold itself by cylinder two.
I've pretty much decided that I'm going to go the manifold route. Does anyone have any experience with removing these things? The Haynes manual warns about the bolts, and I don't want to break them off. Is this something that should go to the shop? If so, what kind of labor am I looking at?
The labor would be ECRUTIATINGLY expensive. Start a couple of days before you are going to try and remove them and spray the hell out of the bolts with WD-40 or some other rust remover spray for tough bolts. Then you should be able to back them out. If you still don't want take the chance, call some of the local exhaust shops and see what they would charge. Some have their own "special" ways of getting the bolts out and they can also install the headers for you fairly quickly. Last I checked the labor rates were at about $45 an hour.
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