2004 F150 5.4

I bought the truck in january of 09. The truck had phasers replaced from the previous owner. I noticed a knocking tapping noise last spring louder than any normal sound the motor makes. I took it to ford in the summer and they replaced the fan clutch thinking that was the problem lol. I take it home and still the same issue. That was all done last year.

The noise never went away. The sound started to get louder a month ago. Sometimes i will get a rattle/knock sound on cold startup. But 90% of the time the sound comes after the motor is warmed up. For an example, driving to walmart and coming back out like 10 minutes later. I start it up and there is that annyoing knocking sound. Can be heard through the wheel wells, and at the front of the motor. The sound doesnt go away above 1200rpm. It lasts for a couple minutes. Sounded more like lash adjusters to me.

2 weeks ago i took the truck to ford and they put in a new phaser on the left side of the motor and the sound was still present. They then put new lifters in the left hand side. They didnt hear the noise again and said it was good to go. I picked it up and took it home. 10 minutes later i started it back up and what do you know. Same noise again! Took it right back to the dealer. I just got it back friday. What they did was put some conditioner in the oil and ran it for a while then checked it over good and the sound isnt near as loud or happen as often. But it is still there. They were thinking there could be a piece of silicone in one of the oil passages caused be a faulty oil filter. I use nothing but motorcraft oil and filters. And change oil and filter at every 2500 miles. I have no idea about the previous 2 owners.

They tell me maybe there could be engine sludge. Which may be causing the problem as well. My thinking is, if there was sludge bad enough to cause the problem. Wouldnt I see any in my oil? And I would think they would see some when they took the valve cover off. Maybe im wrong.

Im going to drive it for a week to just give it a little time yet. Then ill be taking it back in. Im worried what they might find if they have to break it open further and my warrenty doesnt cover the issue. This problem is getting very annoying. I have never had a problem performance wise with this motor. It runs great other than the knocking.

Anybody else ever have the issue im having?

 

You might want to read this post:

https://www.ford-trucks.com/forums/9...id-sludge.html