Article No. 02-8-1

• ENGINE—4.0L SOHC—RATTLE NOISE FROM PRIMARY CHAIN DRIVE AREA BETWEEN 2000-3000 RPM—COLD ENGINE OPERATION ONLY

• NOISE—RATTLE NOISE FROM PRIMARY TIMING CHAIN DRIVE AREA BETWEEN 2000-3000 RPM— COLD ENGINE OPERATION ONLY—VEHICLES EQUIPPED WITH 4.0L SOHC ENGINE ONLY

FORD: 1999-2002 EXPLORER; 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER

MERCURY: 1999-2002 MOUNTAINEER

This article is being republished in its entirety add Ranger to the Labor Time Table.

ISSUE
Some vehicles equipped with the 4.0 SOHC (Single Over-Head Cam) engine may exhibit a Primary Timing Chain rattle noise. The noise is audible during hot and cold engine operation (but predominantly found on cold engines) under acceleration, typically at 2400-2500 rpm. To confirm presence of this noise, accelerate in 2nd gear between 2000 and 3000 rpm and listen for rattle noise that sounds similar to spark knock. This maybe caused by the Primary Timing Chain Tensioner system.

ACTION
Replace the Primary Timing Chain Tensioner, Chain Guide, Jackshaft and Crankshaft Sprockets with a Primary Timing Chain Tensioner Kit. The Kit includes an improved Primary Chain Tensioner, as well as updated Primary Chain Guide, Jackshaft, and Crankshaft Sprockets. Required fasteners, primary timing chain, and front cover gaskets are also included. Refer to the following Service Procedure for details.

SERVICE PROCEDURE
Verify the condition. Obtain the correct Primary Timing Chain Tensioner Kit and follow the instruction sheet supplied with the Kit.

Use Kit 2U3Z-6D256-AA (balance shaft engines) for:
• 1999-2001 4X4 Explorer/Mountaineer
• 2001-2002 4X4 Sport/Sport Trac
• ALL 2002 Explorer/Mountaineer, except engine codes 2G-960-AA and 2G-964-AA.

Use Kit P/N 2U3Z-6D256-BA (non balance shaft engines) for:
• 1999-2001 4X2 Explorer/Mountaineer
• 2001-2002 4X2 Sport/Sport Trac
• 2002 MY Explorer/Mountaineer with engine codes 2G-960-AA and 2G-964-AA
• ALL 2001-2002 Ranger

OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 02-7-6
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OASIS CODES: 497000, 615000, 615500