timing chain rattle resolution
I have no first hand knowledge of the 2002 and later SOHC V6 but I suspect it is similar to my 2000 except for the one piece intake manifold. Many of the timing chain components were changed in 2002 due to early failure on the 2nd generation engines. 65K miles seems low mileage to be experiencing chain rattle. Has the engine oil and filter been changed at the scheduled intervals?
There are three possible sources of timing chain rattle - right rear, left front, center front. Have you attempted to locate the source? A section of flexible hose held to the hear can work almost as well as a mechanic's stethoscope.
I believe Ford suggests the following resolution process:
1. Replace front and rear upper tensioners and oil return restricter. The intake manifold must be removed to replace the front upper tensioner and restricter.
2. Install primary timing chain kit (replaces jackshaft chain, crankshaft and jackshat sprockets, tensioner and guide. The front timing cover must be removed (and everything above it) to install the kit.
3. Replace left front timing chain cassette. Requires removing front timing cover and valve cover.
4. Replace right rear timing chain cassette. Requires either removing engine (preferred) or transmission.
The rear cassette usually lasts the longest but in my case it failed before the front cassette. The jackshaft chain tensioner is usually the first to fail.
I always encourage members to determine what is actually failed before buying parts. In general, it is a less expensive approach but may result in the vehicle being unusable for a longer period. Unfortunately, it takes several hours of work just to remove the valve covers to inspect the upper parts of the cassettes. If any of the guides are broken, you should remove the oil pan to extract the pieces to keep them from blocking the oil pickup screen.
