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Did a search and have come to the conclusion that these are some noisy motors. Nothing I found was the same as the problem I'm having.
I have a 98' e250 van with a 5.4 that has devloped a knock that comes and goes. The scary thing is it sounds exactly like a spun rod bearing (little guy inside with a hammer). Rpm, load,etc seem to make no difference. The fact that it comes and goes is what gets me. Oil has been changed regularly 5w30, no over heating or abuse.I did the poor mans stethoscope and the noise is definitly coming from the passenger side head. Haven't had time to pull the valve cover yet, and the design looks like it's going to be a PITA when I do anyway.
Anyone have any ideas what it could be?
While yes there are 2 broken studs on the exhuast manifold, I'm going to have to say thats not it. The lash adjuster maybe, but would it really be that loud? Still haven't had time to tear into it, maybe tomorrow.
Ok finally got time to work on it. Just got the vavle cover off and can't see anything obvious. Looks like I get to go to Ford and buy a vavle spring compressor. Next question would be, is there a way to test the lash adjusters? Almost forgot, I took the doghouse off and took it around tha block before tearing into it, Definitely not an exhaust leak, the manifold does leak, but my knock is there too. About half engine speed so I'm leaning towards it definitely being a lash adjuster.
You need to run the engine and cut off each cylinder (1 at a time by pulling the injector connector and see if the noise goes away to determin which cylinder it is)
Update, pulled the belt, no change,disconnected one coil pack at a time, no change, took both valve covers off and inspected,(passenger side isn't too bad but the drivers is a PITA) found nothing that wasn't right. I thought I was stumped before......... The wife just had my second son last week so between work and whats been going on at home I haven't had a lot of time to work on it. Anyone got even a guess on what it might be? Has anyone ever heard a torque converter make a noise like a spun bearing? If you can't guess I'm grasping at straws now.