I have obtained a nearly new 5.4L Triton to replace the motor with a bad # 1 connecting rod bearing in my '97 Expedition. When I get that motor out, I intend to take a close look at the # 1 hole to see if I can learn what happened. I also intend to take careful measurements throughout the motor to learn what type of wear can be expected after 113,000 in a well-maintained 5.4L. This motor has never made any sort of start-up noise except for the knocking of the bad CR bearing. I also now have a 5.4L 2001 Expedition with 68K miles, and it also makes absolutely no start-up knocking, slapping, rattling, or any other sort of noise.

 

There is nothing like an autopsy. Can you post pictures? You will have many interested readers.
Thanks!

 

I may need to breakdow and buy a new digital camera.

 

Just went through buying a digital camera back in January, If you want a good one, buy a Nikon D70 DSLR......

 

I'm considering getting my wife a 2005 Expedition XLS, I have found the 4.6L engine to be no longer available in these, and the Expeditions now all have the 5.4L 300hp engine. Does the 300hp engine have the same short skirts, will it have the same engine knock problems? Isn't this the same 5.4L that went into the 2002-up Navigator? Haven't many of them been replaced for very early failures, head gaskets, knocking?

She won't like knocking, even if it is normal. She would have hated my 2.5L 1988 Buick Century, it knocked like crazy, as did my 2.5L 1988 Chrysler LeBaron and 2.5L 1987 Chevy Celebrity and 2.2L 1985 Dodge Charger, and basically any big 4-cylinder I ever owned.

I've heard this noise, former boss has a 1998 EB Expedition 5.4L, when cold it knocks hard for a minute.

I've had a rod knock in my van once, after it sat two months without being started, and someone let out the oil, I topped it off, added a new filter, and it knocked for about four seconds. Hasn't made a bad sound since (from the engine, rest of the van, well...I'll shut up now)

 

Hey Occ!
I've never heard such a litany of knocks!
Who was responsible for maintaining proper lubrication in all those vehicles?

I've got a '98 Club Wagon with a 5.4L engine. It has no "cold knock" problems whatsoever. I never would have heard of this problem, outlandish as it is, if I had not stumbled upon this discussion.

 

Although I haven't purchased a Ford yet (I put a deposit on an '02 F-0150 S'crew FX4), this issue isn't only a Ford problem.

My '01 Dakota Quad Cab with 3.9L V6 also has a knock during initial startup which lasts for about 1 - 2 minutes. Also, spark knock is prevalent, especially during towing, whenever a load is applied. This is even stated in the owners manual that spark knock is normal - who has heard of something so absurd? I've worked as a QA Eng in the automotive dealing predominantly with Chrysler and GM but they are all the same. Wherever a flaw is detected, they try to mask it.

Getting back to this thread, I'm very leary about purchasing this truck now due to the issues that I've read about the realiability of the 5.4L. Seems like the 4.6L is better.....maybe I should stick with the Dakota since it is in showroom condition with 125,000 babied KM's. At least the Dodge hasn't begun to rust as that '02 FX4 has - my frame has very little rust. I will purchase another truck, and I do know that it will not be a Dodge, but now I'm contempating GM which still isn't better.......it certainly won't be a Honda!!!

 

I have had no internal engine problems with my 2001 5.4L, no knocking, no plugs ejecting from the heads.
For every 1 truck that you read about that has a problem, there are several hundred thousand that do not. I wouldn't be scared of it.

 

My 5.4 3 valve does this. I have about 1000 miles on it only. Cold start makes you wonder if all is ok. But given a few moments it stops and goes like a rocket. This 300HP engine is pretty quick evn carrying an Expy and my fat butt!

 

I have an '01 150 with the said 5.4. It does make a very slight knock at cold start-up. It goes away within a couple a moments time, and is otherwise smooth and quiet. It also has 112,000 miles on it. I bought it new, I noticed it somewhere along the way, and wasn't too concerned about it. It hasn't gotten any worse, I always start it as I'm about to leave the house, and by the time I remember everything, she's all sorted out and ready to roll. The engine still has all the power it ever did, Just yesterday it put a Mitsi with a nice big stainless muffler to shame going up a big hill. Don't worry about it.
Rob

 

Have a Sport Trac w/ the 4.6 engine, bought it with 3700 miles just changed the oil at 5,000 miles w/ Mobil 5w/30 (Slick 50) and a FRAM DG2 filter. Have been noticing this
'Thud' when starting the engine cold too [without the A/C on] !!! Will go to deler tomorrow (only have 6700 miles on it) to get engine oil changed immediately with Ford Motorcraft filter. Will report back by end of week to see if this change corrects the problem.

 

The 04 5.4 are good motors what i ve seen in the wives truck it has 40000+ on it.She use to walk all over my 00 F150 4x4 7700 5.4, got tired of that and enhanced it a little now she can t catch me .Mine has this knock every one talkin about but it stays for hours[wheelwell noise]the truck is used for piloting ,has155000kms,but iam going in to see what they can do while i have warrinty.The 04 is very quiet and has had a hard 40000+ life.Buy one again HELL YEA best darn motor going easy to improve HP.Check out my gallery its under Driveway Of FORDS P.S I read every post and agree with you all if it bugs you dont buy it but dishing out cold cash requires research and info this place has it all

 

[QUOTE=exdodgeguy]Getting back to this thread, I'm very leary about purchasing this truck now due to the issues that I've read about the realiability of the 5.4L. Seems like the 4.6L is better....."/QUOTE]


I recently tore down and analyzed a 5.4L with 114,00 miles. Except for one connecting rod bearing which failed from an unknown etiology, the motor was in remarkable shape. None of the parts "exposed" to friction had any measurable wear. Parts showing NO measurable wear, including cylinders, pistons, piston rings, connecting rod bearings, main bearings, cranshaft journals, timing chains, cam shafts, valve stems, valve seats, etc. I conclude that a properly maintained and driven 5.4L easily will go 300,000 miles before suffering wear-related symptoms. Use Mobil 1 or Amsoil synthetic oil and a Mobil 1 oil filter (it is only $6 more than motorcraft). The chances that a 5.4L Triton would disappoint you are vanishingly small. If you're a car guy or gal, you'll love this motor. I bought a second Expedition just for its 5.4L -- well, . . . . there were other things, but the motor was a significant factor.

 

Dumb & dumber... Dealer's mechanic proved to me today that my thud was the AC compressor kicking in on my 4.0 V6 SOHC (SportTrac) when I started engine. Large thud doesn't occur when A/C is cut off

upon starting engine. Plus just cutting A/C off before cutting engine off doesn't mean cycle for cutting in & on is complete.

Guess that's why they charge $85 dollars and hour for diagnostic work....

 

The 04's have longer piston skirts to keep the noise away. Though, the noise is harmless, they changes the pistons so people would stop complaining.
I have heard of noises from the variable cam timing assemblies on the 04's though.