97 5.0 engine clicking mystery

[kenfrmcal]

This one has me stumped...my mechanic too. I have a 97 Mountaineer AWD with a 5.0 that is making a clicking noise that everyone who heard it said it sounds like lifter clatter. SO, I got into the engine and replaced all 16 lifters with new Ford racing hydraulic roller lifters. A ***** and a half of a job!! Got it all back together, started it up and.....it still clicks!!! ARG! The sound is most noticeable at about 1100-2000 RPM. At idle it clicks once in a while and above 2000 it goes away. What's really strange is that it runs great! I just got back from towing my boat 1200 miles with no problems. I've even tried running the piss out of it down the freeway to get it to fail but NO! My mechanic checked it over, thought it might be a cracked flex plate, pulled the tranny, but NO! It seems to come from the lower end and/or the driver side but it's hard to pin down. Definately a mechanical sound. So anyone out there have any experience with this or any ideas? IT's DRIVING ME NUTS!!!!! :roll:

 

[performancenut]

Well, the "click" on my 1997 5.0 is an exhaust manifold leak. Pretty common on these engines; exhaust manifolds like to crack and let out a small amount of exhaust depending on temp. and pressure. Usually more pronounced when cold; as the metal heats up and expands the sound decreases.

 

[Cali' Explorer]

Reacenut is right, first thing to check is the Exhaust Manifolds. If that is the leak, make sure to use some Percy's Dead Soft Aluminum Gaskets and some Stage-8 Locking header bolts so that it doesn't ever come back (or you'll be wishing you had done that like I am now).

Another place to check is the Collectors. It doesn't seem like a lot of people have problems with the colectors but I have had problems with my Collectors leaking ever since Ford put new Exhaust Manifolds on.

Good luck, and if you find something out besides one of the above, please tell me because I've got the exact same tick. I will eventually replace the Exhaust Manifold gaskets with the above one's, but for now, it runs ok so I'm not too worried about it.

 

[james t]

99.99% chance its either the passenger side manifold or the EGR tube. They all do it... in fact ive never heard a stock 5 liter X that didnt leak. Fixed mine with new header gaskets.

 

[performancenut]

I'm waiting for the headers (will they ever arrive one way or the other?) and will do the swap with new gaskets, etc.

 

[Cali' Explorer]

Another possibility I hadn't though of until now, Spark Plugs and wires. Seems silly, I know, but I've had a nasty tick, clack and rattle for last 2 or 3k which I was sure was exhaust related.

I just changed the spark plugs and reset the computer and when I first started it, 90% of the ticking/clacking/rattling was gone. I don't want to say it was all gone, because it wasn't, but for the first minute or two of driving, there was no noise at all. It has come back a little, but its about 80% less than it was before the change.

The good thing about this too me is it says that if it isn't the Exhaust Manifold's, its most likely either a sensor or something wrong with the computer. Time will tell, but if I find an answer to the Clicking Mystery before you do, I will be sure to tell you what I find.

 

[performancenut]

A bad plug wire and/or connection can "arc" and result in a snapping noise (electrical energy conversion to sound energy) and frequently can be seen by observing the engine at night/in dark while running and looking for a flash of light.

 

[Nitrous SSC]

I totaly agree with James T.

 

[kenfrmcal]

Well guys....it's not the plug wires...this is a definate mechanical clicking...not the snapping sound of arcing spark. I just did a tuneup with new plugs and wires anyhow. SOooo....the next thing is to investigate the manifolds. I've heard several people say that the crappy stamped steel welded manifolds crack and make the clicking sound like lifters. Maybe that's why Ford switched over to cast iron in '99!!

 

[Drewfus04]

I have a clicking at idle once 'n a while with my '98 4.0 as well. I took it to a ford dealership and they told me it was the belt/tightener. They replaced that and bam, nothing. I was thinking the whole time they were telling me, "Yes sir, that is exactly the problem.. look at the belt, it's all worn." I'm thinking... wtf-ever buddy. A belt making a ticking noise, no. My father tells me it might be the lifter but no mechanics can narrow it down really... I wonder how sometimes when it's been drove for a while that the noise just disappears when I start it back up. But when it starts for the first time in a couple hours or so, it clicks like mad.

Please help!!!

 

[Mbrooks420]

I agree with James that all 5.0's I have ever heard/test driven leaked at the manifiolds, and have that dreaded tick. Drewfus, have you had the timing chain tensioner recal yet? A SOHC with motor noise is suspect.