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.
TICKING AND / OR KNOCKING NOISE / STARTUP RATTLE FROM ENGINE - 4.6L / 5.4L 3V
FORD:2005 Mustang2004-2005 F-1502005 Expedition, F-250, F-350
This article supersedes TSB 06-4-7 to update the Service Procedure.
ISSUESome 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.
ACTIONBefore 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.
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.
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.
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:
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.
here is the chain timing
I just did the phaser this way without the lash adjusters
Timing Drive Components