Judging from the recent increased posts about piston slap in the 5.4 motors, it looks as though this problem could become as notorious as the dreaded door cracks. I thought I had avoided these prolific problems (body door cracks and engine oil leak from pass. side head gasket) by buying a 2001…WRONG. I too have this piston slap (ticking/knocking at start up) @ just 30K miles, it’s a Windsor built motor. I think if I had a choice, I’d choose a door crack over a hosed engine. It’s been to the dealer who of course couldn’t hear it, so I told them keep it another night and I’ll be in in the morning to prove it to them and sure as sh_t it was quite. So just for giggles they replaced my serpentine belt as they have a TSB for some belts making noise. So I think OK, maybe that’s it, well two days later the piston slap is back with a vengeance. So I’ll be visiting them again soon.
What sucks is that in all likelihood the motor will go 100K+ miles with this problem, but probably doesn’t have a chance in hell of seeing 200K miles. Now I feel as though I’ll HAVE to purchase an extended warranty just to ensure that I can go at least 100K miles. I’m not convinced that dropping a new engine in is the answer either, I could end up with another problem motor and have something else get screwed up by a hurried mechanic in the process. I try to run my vehicles for 10 years before giving up on them, but it doesn’t look good for this one. It’s the first P.U. I’ve ever owned and the newest vehicle I’ve ever owned and I love it, but this situation sucks. It used to be only Chebys had piston slap issues.

 

They have driven trucks with piston slap over 200K. If you research this forum you will find quite a bit of info about it. I don't think your year is affected.

 

Piston slap can occur in any internal combustion engine. It is not brand specific. I had a slap in a brand new 1978 Mercury Cougar with the 351 v8. The dealer rep gave me two choices, and extended warrenty or repair the engine. I chose the engine repair, and the dealer tore the engine down and replaced the #2 piston. The engine ran flawlessly for the next 90,000 miles until I sold it.
I believe the engine would have lasted just as long without the repair, but I didn't want to listen to that cold start knock in my new car.
If I were you, I would insist on a new short block.
Good luck.



Bru

2002 F150 Super Crew
Black 4X4 Lariat
5.4 Engine Ford Chrome Bars
Ford Bedliner

1979 Bronco 351M 75K orig.

 

I have the 2001 with the 5.4 and 26K miles. The piston slap started about two months ago and is getting worst. Ford said they are looking into this due to so many complaints. (Believe that and I'll tell you another)They wont do a dame thing about it. It's just not right! My dealer said it's clearly Piston slap and do want to replace the engine but Ford wont let them!!! The consumer gets screwed again!!!
No place to go!!!
The other guy said it right.
This is Ford's way to get extra money from us by making us purchasing an extended warranty.