Garyle, I stumbled upon the following discussions that may be of your interest.
https://www.ford-trucks.com/forums/8...sure-loss.html
http://www.google.com/search?hl=en&c...nty%3F&spell=1

 

Thanks for the link khang.....that TSB just about says it all. Did you notice the 2005 expy's referenced in the TSB? Now it's just a matter of what the quick lube place (and Ford) will do to place blame on the customer. I have all the records from this vehicle being serviced both from Ford and the quick lube place and there has never been a note indicating engine noise or low oil pressure. In addition, the quick lube place indicates they follow the manufactures maintenance schedule and equivilant parts. So if the engine (as in the TSB) knocks, ticks, rattles etc as a result of low oil pressure from aftermarket filters, what do you suppose that is.....elf's with little nerf hammers or metal to metal? My other Expy and SD have a combined nearly 300K with no issues yet from the same lube joint. My guess is that is about to change......At least when I lost oil pressure I was close to home, unlike the guy in the other post with the seized V-10.

 

That's good news, I hope it works out from here. I'd like to say that my trucks never have anything other than Motorcraft. While this is true, in the time that I have owned it, I buy all my vehicles pre-owned (used). There's no telling what the previous owners oil change interval or even what filter they used. When I bought my 06, it had a white filter with black writing! I immediately changed it, even though it just had an oil change completed.

 

New member here. How is everyone?

I have the clatter problem as well. I read through this thread and will try the recommended troubleshooting tips as well.

OP, how did everything turn out so far?

 

the wally worlds here mark there filters with who did it the date and the store number.

 

Update. I changed the oil and motocraft filter to inspect for more damaging metal. The filter still had minor traces of metal in the filter fabric but nothing like the aftermarket filter that seemed to lose oil pressure. I also disassembled the motocraft flter and a TVI filter from another oil change. Sure enough, the Motocraft filter has what appears to be a durable silicone check-valve diaphram where the TVI has a piece of cheezy rubber instead.
The vehicle as stated earlier is still running as quiet as day 1. Not even an injector tick. The Royal Purple seems to really quiet the motor down to the point where you start hearing other mechanal noises you never heard before...power steering, belt, pulleys etc (I would hope so since I have now spent $110.00 on 2 changes). A Ford mechanic said he has seen this kind of failure before, and the damage occurs on the rear passenger side upper end....last in line for the oil train. He did not say how long I have before everything lets go because the ones he sees he fixes before they die.
I have not yet taken apart the suspect oil filter because I'm still waiting on a response from the Quick oil place manager.
For those of you trying to compare your phaser tick or rod knock, this was not the case. I lost oil pressure in part of the engine and it was clattering very loudly up top on the passenger side. I flushed the engine in good shape with kerosene and refilled with synthetic and a motocraft filter and it runs quiet now. With the amount of metal in the TVI filter, I would have thought the motor would be trash by now. There was a guy on another thread that had the same thing happen and his siezed up a short time later on the highway.
Interestingly, I went to a quick change place because Ford stuck me for $1100 on a warranty issue so I figured I try out someone elses warranty. What do you suppose I will get when I show up with a 5.4 that runs quieter than most others, an oil filter full of metal and a Ford TSB that says I shouldn't run their filter? I think we all know.