Need Some Help, Knocking Sound from Upper intake | Ford Explorer Forums

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Need Some Help, Knocking Sound from Upper intake

Medcop222

New Member
Joined
February 20, 2012
Messages
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City, State
Hot Springs Arkansas
Year, Model & Trim Level
1996 Ford Explorer 5.0
Hello Folks,

I am in need os somw help here. I have a 1996 Ford Explorer 5.0 4 door XLT that was given to me when my father passed away. I am restoring it to be my daily driver. Will be my first Ford in a LONG time. Dont normally work on Fords, so im coming to the experts ( you daily Ford drivers and lovers) for your advice.

Blew a head gasket and started getting tapping noise inside the intake, Replaced everything and now getting a very loud knocking noise, sounds like someone hammering on the inside of the intake, and running very rough. Below I will describe what all I did to give you a better idea of the progression..

Had Crack in raidiator, finally blew
Blew Head Gasket, water in oil ( still running, no obvious damage)

Tore down, Had heads redone, new timing set, new water pump, all new gaskets, pulled, cleaned and re-oiled all lifters, push rods tumbled and cleaned.

Pulled apart upper intake and cleaned all oil out, replaced plemtum gaskets, EGR gasket, AIC Gaskets and TBI gaskets.

New Plugs, Wires, Pulled and checked Syncro and CPS. Replaced and realligned Syncro.

Put everything back together and have this LOUD knocking sound coming from the intake. Pulled intake off and turned engine over, No noise, knocking ect.

Changed the AIC to another one ( was used but no slack or play) with no change.

Through some research I have read that these intakes have a problem with breaking intake runners or baffles on the inside and have problems with the EGRs. Mine does not have the EGR tube that hooks the the ext manafold.

This thing is driving me crazy so any help would be great. Surely someone else has had this problem.

Any help will be appreciated for a new Ford Owner.

Jeremy
 






One thing that comes to mind is a possibility of an intake valve that isn't closing causing the noise in the intake. Unless of course the plug wires are crossed on two cyl. If the wires aren't the problem, take the air filter out so you can listen to the noise. A backfire into the intake is loud but is more a pop than a hard knock.
 






You were exactly correct. My rocker arms had loosened up and the valves were not opening. Thank you. I hadn't considered that.
 






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