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Ironmike
Ironmike, Ford Technician
Category: Ford
Satisfied Customers: 3301
Experience:  30 years ASE Master tech L1 . Ford master
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Tvariable canshaft timing 05 f150 5.4 v8ype your request h

Resolved Question:

Tvariable canshaft timing 05 f150 5.4 v8ype your request here
Submitted: 5 years ago.
Category: Ford
Expert:  Ironmike replied 5 years ago.

Greetings,

There is a noise, performance issue with these, I did 2 when they first came out and the enginer came by on what is the repair. They did them as a customer noise annoyance warranty repair. First they said pull the engine, then they mabe us buy special tools to wedge the chain and slide the passenger side out with the valve cover off. I would call ford customer assistance and ask for goodwill. After Ford I wroked with Chrysler service contracts and people don't realize that they will pay on known issues even outside warranty if you ask, especially if you are the first owner.

TSB 06-19-8

10/02/06

TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V

FORD:
2005 Mustang
2004-2005 F-150
2005 Expedition, F-250, F-350

 

LINCOLN:
2005 Navigator

 

This article supersedes TSB 06-4-7 to update the Service Procedure.

ISSUE
Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking and I or knocking noise after reaching normal operating temperature, or a rattle upon starting. The noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a normal characteristic of these engines. In other cases the noise may require further investigation. Sorting out and defining the noise as reported by the customer is important to successfully diagnose and I or repair the condition.

 

ACTION
Before starting diagnosis, it is critical to determine the specific engine noise the customer is concerned with. The customer should be interviewed to get their detailed perception and description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the symptom. Refer to the following Service Procedure to help determine the source of the noise and if a repair is needed.

 

SERVICE PROCEDURE

NOTE READ THIS SECTION IN ITS ENTIRETY BEFORE BEGINNING.

 

NOTE THE 4.6L 3V AND 5.4L 3V ENGINES ARE INSTALLED IN SEVERAL VEHICLE PLATFORMS, WHICH MAY INFLUENCE THE INTENSITY OF NOISE DUE TO VEHICLE DIFFERENCES IN SOUND TRANSMISSION PATHS, HOOD AND BODY INSULATION PACKAGES, AND ROOT CAUSE OF THE COMPONENT(S) CAUSING THE NOISE.

 

PRE-CHECKS

1.Make sure you have a detailed description of the noise the customer is concerned with, including whether the noise is occurring at idle or above idle speed (does it disappear above 1200 RPM), and if the engine is cold, hot, or both when the noise is occurring. These engines generate a lot of "normal" noises, so it is critical to confirm the noise the customer is concerned with. Determine what environment the customer is in when the noise is most noticeable to them (inside passenger compartment, next to building with / without the driver and / or passenger window open, or beside the wheel well). Validate by using your own perception.

 

2.Compare the noise generated with a new vehicle, if available, with an ENGINE build date of 3/30/2005 or later on Mustang and 4/18/2005 or later on F-150 to F-350, Expedition and Navigator vehicles.

 

3.Diagnose noise when engine is at normal operating temperature (Oil at 160°F (71°C) or above). Verify oil temperature by using a diagnostic scan tool and monitoring the engine oil temperature (EOT) PID. Startup rattle may only occur with cold oil.

 

4.Check the type of oil filter installed on the vehicle. A dirty or clogged filter may cause a pressure drop. Look for aftermarket brands not recognized in the market or a production filter that has gone beyond the standard Ford recommended change interval.

 

5.Check for signs of oil brand used and viscosity (interview customer if needed). Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil or equivalent is recommended.

 

Once the above pre-checks are complete, check for sound level from the following components, in the order listed. Compare the sound from these components to the noise the customer is concerned with, to determine the source of the noise.

INJECTION / FUEL SYSTEM

Injector noise (ticking) is considered normal. Noise increases with RPM hot or cold and is recognized at the top of the engine.

VALVE TRAIN

Lash adjusters can make a ticking / tapping noise noticeable at any engine RPM / temperature and is audible through the wheel well or an open hood. However, with the hood down, lash adjuster noise can be heard as a light tapping noise through the wheel well and is considered normal.

Tracing this noise must be isolated to a cylinder bank. If one bank is louder than the other bank, focus the diagnostic to the loud bank. If both banks seem loud with the hood down, compare wheel well sound level to another comparable vehicle.

Use a stethoscope on the top of the cam cover bolt heads to confirm which bank is affected. Move the probe from front to rear if necessary.
If isolated, only replace the intake and exhaust lifters on the affected cylinder bank.

 

VARIABLE CAM TIMING

The 4.6L 3V and 5.4L 3V variable cam timing (VCT) feature may emit a light knock in normal operation and is audible only at idle speed, with a hot engine (gear selector in park I neutral). However, it may be masked by or mistaken for other noises generated from either injector firing or a malfunctioning valve train as described above. The noise does not affect performance or durability of the part.

VCT phasers may knock at hot idle. It may be heard inside the passenger compartment, or the wheel well area. Some light noise is normal. The engine may require a cold soak overnight for a full diagnosis to effectively be made at hot idle, particularly when a VCT phaser is suspected. The knock is not prevalent at cold temperature.

To test for VCT noise:

1.Place the transmission in park or neutral

 

2.Bring engine oil temperature to 160°F (71°C) or above as indicated by the scan tool "EOT" PID.

 

3.Allow engine to idle, and determine if noise is noticeable.

 

4.Set engine speed to over 1200 RPM (if noise is a VCT knock, the noise should disappear).

 

5.Return engine speed to idle (verify knock returns).

 

If the noise intensity is more than a lightly audible knock at hot idle under 1200 RPM at engine operating temperature, replace the cam phaser using the "In-Vehicle Repair" Camshaft Phaser and Sprocket procedure found in the Workshop Manual, Section 303-01

START UP RATTLE

Some 2004 F-150 and 2005 F-150, Expedition, Navigator, F-Super Duty, and Mustang vehicles may have a rattle on startup that lasts 1 to 3 seconds. If initial pre-checks have been completed and the noise sounds like it is coming from the front of the engine, replace the VCT Phaser Kit. If the engine continues to make the rattle noise after the initial startup do not exchange VCT.

 

Good luck

Customer: replied 5 years ago.
We know the left cam is out of time. The rougher the engine runs the ticking noise is loudest, no matter the engine temp. I like your suggestion on the oil filter, because i think something in the oil caused a malfunction causing the cam to jump time, I apppreciate your time and answers, but what I really need are blow ups on the parts in the variable timing mechanisms. This problem is hardly noticeable at times, but it really affects the performance at others. If you have no other suggestions. I will acept your reply. thank you
Expert:  Ironmike replied 5 years ago.

Greetings,



Special Tool(s)

Removal

  1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional information, refer to Camshaft - RH. See: Camshaft\Service and Repair
  2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional information, refer to Camshaft - LH. See: Camshaft\Service and Repair
  3. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components. See: Timing Components Remove the camshaft phaser and sprocket from the timing chain.

  1. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
    • If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.
  1. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.

  • If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be installed.

  1. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or spring is deformed or damaged (B), install a new camshaft phaser and sprocket.

Installation

  1. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new camshaft phaser and sprocket.
  2. NOTICE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.



Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.

  1. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional information, refer to Camshaft - RH. See: Camshaft\Service and Repair
  2. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional information, refer to Camshaft - LH. See: Camshaft\Service and Repair

here is the chain timing

I just did the phaser this way without the lash adjusters

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2005 Ford Truck F 150 2WD Pickup V8-5.4L SOHC VIN 5

Vehicle Level Engine, Cooling and Exhaust Engine Timing Components Service and Repair Timing Drive Components
Timing Drive Components
Notes

Timing Drive Components



Special Tool(s)



Material

Removal

  1. Remove the engine front cover.

  1. Remove the crankshaft sensor ring from the crankshaft.

  1. Position the crankshaft keyway at the 12 o'clock position.

  1. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock. The number 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the number 1 cylinder.

  1. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Remove only the 3 roller followers shown in the illustration from the RH cylinder head.

  1. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove the 3 designated roller followers in the previous step from the RH cylinder head.

  1. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Remove only the 3 roller followers shown in the illustration from the LH cylinder head.

  1. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove the 3 designated roller followers in the previous step from the LH cylinder head.

  1. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.

  1. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Remove the bolts, the LH timing chain tensioner and tensioner arm.

  1. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Remove the bolts, the RH timing chain tensioner and tensioner arm.

  1. Remove the RH and LH timing chains and the crankshaft sprocket.

  1. NOTE: RH shown, LH similar. Remove the LH and RH timing chain guides.

  1. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. Using the special tool, remove the bolt and the RH camshaft phaser sprocket assembly.
    • Discard the camshaft phaser sprocket bolt.

  1. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. Using the special tool, remove the bolt and the LH camshaft phaser sprocket assembly.
    • Discard the camshaft phaser sprocket bolt.

  1. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from sideloading. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Remove the bolts in the sequence shown and remove the RH cylinder head front camshaft bearing cap and then the remaining bearing caps.

  1. Clean and inspect the RH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
  1. Remove the RH camshaft.

  1. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from sideloading. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Remove the bolts in the sequence shown and remove the LH cylinder head front camshaft bearing cap and then the remaining bearing caps.

  1. Clean and inspect the LH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
  1. Remove the LH camshaft.
  2. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Remove all of the remaining roller followers from the cylinder heads.

Installation

  1. Install the LH and RH camshafts.
    • Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

  1. NOTE: LH shown, RH similar. Install the LH and RH camshaft bearing caps in their original locations.

  1. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: LH shown, RH similar. Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight.

  1. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. NOTE: LH shown, RH similar. Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages.
    • Stage 1: Tighten to 40 Nm (30 ft. lbs.) .
    • Stage 2: Tighten an additional 90 degrees.

  1. Position the crankshaft with the special tool, then remove the tool.

  1. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. Compress the tensioner plunger, using a vise.

  1. Install a retaining clip on the tensioner to hold the plunger in during installation.
  2. Remove the tensioner from the vise.

  1. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.

  1. Install the crankshaft sprocket, making sure the flange faces forward.

  1. Install the 4 bolts and the LH and RH timing chain guides.
    • Tighten to 10 Nm (89 inch lbs.) .

  1. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.

  1. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.

  1. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts.
    • Tighten to 25 Nm (18 ft. lbs.) .

  1. Remove the retaining clip from the LH timing chain tensioner.

  1. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.

  1. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.

  1. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts.
    • Tighten to 25 Nm (18 ft. lbs.) .

  1. Remove the retaining clip from the RH timing chain tensioner.

  1. As a post-check, verify correct alignment of all timing marks.

  1. Install the crankshaft sensor ring on the crankshaft.

  1. CAUTION: If the components are to be reinstalled, they must be installed into their original locations. Using the special tool, install all of the camshaft roller followers.
    • Lubricate the roller followers with clean engine oil prior to installation.
  1. Install the engine front cover.

 

 

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Ironmike, Ford Technician
Category: Ford
Satisfied Customers: 3301
Experience: 30 years ASE Master tech L1 . Ford master
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