Another noise thread..

[Zorin]

EddyB, that's the water passage to the heater core. All 4.6L V8's have had that pipe in there, and some are better than others. The NPI version used a metal pipe with a rubber hose crimp-clamped to it, those failed left and right. Then Ford came up with the PI version of the engine, which used a full metal tube with an O Ring connection into the water pump....much more reliable!

The Modular V8's have always had a dry valley, except for when you blow the intake out of a 2V....then it fills with coolant, and you don't really know because it holds a fair amount before it starts to leak out onto the ground....all you see is dropping coolant levels, and it stinks like coolant, but no visible leakage.

There should be an insulation package under the intake that should dampen a lot of the intake noise. I haven't had the intake off of a 3V in a really long time, but I pull 2V intakes regular, and that housing cracks, and is typically tossed when the intake is changed out...they are usually garbage by that point. And then the intake gets louder for sure!

Tim

 

[07EddyB]

Thanks for the info Zorin. And yes, there was an insulation package present. I can only imagine how it would sound without it! It would make sense at first to close off the back to reduce noise - but the fan obviously blows through the valley so that would be counter productive I guess.

 

[07EddyB]

Well - I did something tonight I never thought I'd never do. I added 6 ounces of SeaFoam to my crankcase and ran it for a few minutes to get it mixed in. The mechanic I took it to was leaning toward a blocked oil passage. I find it hard to believe since I have been extremely good about oil changes but - I did buy it with 19K miles on it so who knows what those first 19K were like. If it works - great. If it doesn't - no big loss. I'm just not comfortable enough with changing the lash adjusters out without proof that they are the problem. You know the drill - don't concentrate on the symptom - find the cause. If it doesn't start - you don't go out and buy a new starter - you start with the battery and the cables. If it's good - then you look at the starter. If I do indeed have a clogged oil passage then putting a new lash adjuster in won't solve anything.
Admittedly, with my recent rash of problems - I have been looking for a replacement. Unfortunately, I prefer body on frame with a V8. You just can't do that anymore without getting into a truck or a full size SUV which just doesn't fit my current needs. I continue to have a disdain for front wheel drive vehicles and it's getting tough to get around that. Sadly, the Toyota 4Runner is about the last viable option. One engine available - 4 liter V6.
I really hate what Ford did to the Explorer in 2011 - I understand why they did it - but they already had crossovers.
Maybe I can hold this guy over until the new Bronco comes out.

 

[PotatoExplorer]

Well - I did something tonight I never thought I'd never do. I added 6 ounces of SeaFoam to my crankcase and ran it for a few minutes to get it mixed in. The mechanic I took it to was leaning toward a blocked oil passage. I find it hard to believe since I have been extremely good about oil changes but - I did buy it with 19K miles on it so who knows what those first 19K were like. If it works - great. If it doesn't - no big loss. I'm just not comfortable enough with changing the lash adjusters out without proof that they are the problem. You know the drill - don't concentrate on the symptom - find the cause. If it doesn't start - you don't go out and buy a new starter - you start with the battery and the cables. If it's good - then you look at the starter. If I do indeed have a clogged oil passage then putting a new lash adjuster in won't solve anything.
Admittedly, with my recent rash of problems - I have been looking for a replacement. Unfortunately, I prefer body on frame with a V8. You just can't do that anymore without getting into a truck or a full size SUV which just doesn't fit my current needs. I continue to have a disdain for front wheel drive vehicles and it's getting tough to get around that. Sadly, the Toyota 4Runner is about the last viable option. One engine available - 4 liter V6.
I really hate what Ford did to the Explorer in 2011 - I understand why they did it - but they already had crossovers.
Maybe I can hold this guy over until the new Bronco comes out.

I know how you feel... I went through a long processes of researching vehicles looking for one that ticked all the boxes. I needed one that could haul my family and all of its crap (especially on vacations) with the option of hauling any additions we may add to the family, A V8 so being underpowered was never an issue (had a 4 cylinder hybrid Escape - that was completely underpowered POS), body on frame, and enough creature comforts/tech to make it feel like I wasn't buying something severely outdated. I landed on the 4th gen Explorer after weighing in other SUV options like the 4Runner (Don't they make a V8 option?), the new Explorer, Cherokees, and Forresters. I thought I would be more happy with my choice, but I'm more "meh" about it, which is unfortunate because I feel like the potential to really love this vehicle is there. I just wish it wasn't so fragile in truck terms...

 

[07EddyB]

So I have the week off and what better way to spend vacation time than work on the Ex.
Pulled the right valve cover off today. Problem was obvious. One of the intakes had a scored and rough cam lobe and and extremely loose rocker. So would this be due to a bad valve lash adjuster or something more serious? I don't believe this is an over all oiling issue as all others looked good. It's just this one valve.

 

[07EddyB]

And now - the rest - of the story.
So the grand finale first - roller seized on the rocker.
Before I popped it out - I turned the engine over manually while my wife watched the cam - the intake valve opened so it's not stuck. Popped the rocker out and the roller was completely seized. The roller is no longer circular - it's worn all the way around so it fought for awhile but it is definitely not round anymore. The cam actually wore a grove in the top frame of the rocker where the roller seized and eventually flat spotted enough to allow the cam to hit the frame of the rocker.
It doesn't look good.
Having said that, I bought a new rocker from the Ford dealer today for $7.40.
Do I need a new cam? Probably. Understand that I did catch it before the lobe flattened. The surface is rough right now but you would need a micrometer to determine just how much of the lobe was worn off. It would appear that the cam metal is harder than the rocker arm metal. That was a good plan if it was intentional.
The plan now - replace the rocker. Most of you know what a camshaft replacement involves on the 4.6. You also know that cam phasers and tensioners and guides are doomed to failure eventually. My current plan is to polish the cam lobe as much as possible - it can't get any worse. Put the new rocker in and run it. When I need to replace the timing components - I'll replace the cam.

 

[GeorgeH]

Hope it sounds great when you finish

 

[Explorer_PL]

I think it may just work fine. The power loss on 1 cylinder may not be noticeable.

Great diagnostic work.

 

[07EddyB]

I think it may just work fine. The power loss on 1 cylinder may not be noticeable.

Great diagnostic work.

I don't think there will be a performance loss. The Ex was not down on power even with the bad rocker. Say what you will about the 3V motors - I've seen first hand a very bad situation - and it got noisy but it didn't drop performance. And it never threw a code.

 

[07EddyB]

So we are all back together and running and the silence is deafening. That was definitely my noise and everything just purrs now. Hope it lasts for a while - I imagine there are worse looking camshafts in operation out there somewhere.

 

[Zorin]

I thought that sounded like a roller follower. Just keep in mind, that while you can polish the cam, the surface won't be great, and it may contribute to accelerated wear on the new follower. You may wind up replacing that follower again when you do replace the cam at timing chain time. In fact, it isn't horrible insurance to do so considering the cost.

Good job in finding the problem, and repairing it!

Tim

 

[07EddyB]

Checking in again - drove it again today. I changed the oil yesterday just out of principle knowing what's been going on inside the engine. Cut the oil filter apart - yes - there were metal flakes on the media. It's quiet - don't know how long it will last but I'm loving it right now. My current plan - oddly enough - is to stand behind it - not dump it ASAP.

 

[07EddyB]

So - I'm resurrecting this thread again to say I may have a problem. Over the past week or so I've noticed a noise at start up - it just lasts a second or so and only does it when it's been sitting for a while. It is a metallic noise. Only does it on the initial start - shut it off and start it again and it doesn't do it. Had the wife start it Saturday but I couldn't pinpoint it - doesn't last long enough. Today I pulled the belt to eliminate an accessory issue - still made the noise. Running, i cant detect a noise difference between the banks even with a screwdriver. I'll be pulling the valve cover next weekend to check on things. Hopefully it's unrelated to my follower issue but it is quite a coincidence.

 

[Explorer_PL]

Maybe start with that one side valve cover and listen to "the" lifter.

 

[07EddyB]

Definitely starting there. It's all very odd - this noise is nothing like what I had before even with the follower issue.