pinging and timing chains!!

[CDW6212R]

Guys, all the SOHC 4.0 engines are the same, that is the parts interchange. The better parts are 2002 design parts. All pre 2002 SOHC 4.0 engines need the better 2002+ cassettes. All cassettes of all years of the engines have plastic guides. The 2002 parts are evidently better, not magically different, just better.

I have countless times mentioned the critical parts, and they apply to all of these SOHC 4.0 engines. The timing chain guides(cassettes) are not ever going to last consistantly over 100,000 miles. They should be changed before then, if they go bad, boom, engine blown. Don't wait for it to happen, spend the minor and annoying costs, and then don't worry about it for another 100k.

(1) front timing cassette
(2) front timing chain tensioner
(3) rear timing chain tensioner

The rear timing cassette was never recalled, even though it is very very similar to the front parts. I changed everything except that in mine(77K). I'll hope to reach 130K to 150K before doing my trans, and that rear cassette. Good luck,

 

[bluestream1]

I would like to clear a few things up here.... First, 1999 and newer vehicles are not involved with the "timing chain/guide rattle" because only the 1997 & 1998 had the plastic timing chain cassette; this was TSB 01M01 The part numbers for updated cassettes for 97 & 98 are different from 99 and up. Newer vehicles should have the update cassette from the factory. Having said that, the 1999 and up are not perfect either and newer models have updated timing chain kits available. In fact they have been updated three times. The rear chain does not seem to be near the problem of the front, and many Techs have never seen a problem with the rear chain.

The timing chain tensioner program, 00M12, can be done up to 72K miles. I still recommend having this part replaced, since the tensioner are known to fail in almost every vehicle that use them. The primary chain tensioners are a little more durable, but should be looked at after 100K, as they will fail in time. Can you spell "POS"

 

[CDW6212R]

Again, they all have plastic guides. Absolutely all SOHC 4.0 Ford engines have plastic on the timing chain cassettes. No matter what year of the engine you have, the cassettes will come as the 2002 design. Again, I did all of that to my 99 last year.

The timing chain tensioners(2) are parts just like the cassettes, they should be replaced periodically, not just when they fail or make noise. When they allow enough slack into the chain(that's the noises), the chain will eventually jump time etc. The valves and pistons will be damaged.

Do not wait, do not waste time for someone to give you an answer that you like better. The parts are very cheap, compared to a new engine. I spent less than $200 on parts. That included the front cassette, both timing chain tensioners, the jackshaft chain and tensioner, plus the balance shaft chain and tensioner.

Parts are hardly ever the problem with a repair, the labor is the big issue. Do the job periodically for a few hundred dollars, and skip the worry and the rebuild. Everyone should be able to get this few hundred dollar maintenance done every 75,000 miles or so. Good luck,

 

[thammel]

Hi Don,

Thanks for the comments and for the picture. Can you either put red arrows pointing to the items or describe exactly where they are in the picture? I presume they are the plastic (tan to beige colored) colored parts on the left and right sides. If we dismantle the front of the engine with it in the vehicle do we have access as per the picture you show? I presume this would mean removing the radiator. I do have an engine hoist, but that just adds to the hassle. Do you really need the special timing tools mentioned in the posts?

Thanks,
Tom

 

[CDW6212R]

If you remove everything from the radiator to the acessories you should be able to do get to the engine front well.

You do have to have the tool kit, it is the only way to time the engine. There are no timing marks. One tool attaches to the balancer, to point to TDC. Two other tools hold one cam in place, while another is used to hold the cam sprocket in place.

The hard part is getting everything off of the top of the engine, and noting where everything goes. The upper intake has to come off just to get to the cam chain tensioner, the TSB front tensioner kit comes with new o-rings.

The front cam cassette is not clearly in the picture. It resides inside the end of each head, you can just see the two sprockets. All of the chains ride along plastic. I decided that while doing the front cassette, I would also do the jackshaft chain, and its tensioner, centered in the picture.

The jackshaft is what you may want to call a timing chain, it runs from the crankshaft to the jackshaft above it. The center shaft isn't a camshaft, it connects to each of the timing chains, one in front, and one in back. A special socket is needed for that jackshaft chain, a torx socket, 14mm possibly. Do not loosen any of the valvetrain parts until you have the special timing tool kit, OTC 6488. If you only loosen that jackshaft bolt, the cams will rotate by themselves etc.

Only loosen the valvetrain parts if and when you have the tool kit ready, and have the engine at TDC. Regards,

 

[CaptKirk]

Does anyone know the waranty on the 04-15-4 tsb?? Did Ford extend it on this tsb?
Thanks

 

[E.B. Cornburner]

So have the '04 models gotten better? Since the TSB was issued in '02, I'd assume the newer ones already have the better components in them.

I've heard this rattle on an '02, but my '04 and others I've looked at were relatively quiet.

They all seem to have a little clatter first thing in the morning for a second till it gets oil pressure. Mine included.

 

[CDW6212R]

The cassette guides were the only really greatly improved parts, those are 2002+ part numbers. The susceptability of certain parts is the same for all of the SOHC 4.0 Explorer engines. The two cam chain tensioners have small steel coil springs inside of them, they will most likely not last 100k-150k or more. They are just like valve springs, in that they will weaken over time. When they weaken the timing chains become more loose, including at start up. The other chain tensioners also rely on steel springs which can become weak.

Old timing chains only had to survive chain stretch, this engine has different parts which the lifespan was not adequately tested before setting maintenance procedures. We are here discussing those, go back and read a 1997 shop manual, they make it sound like nothing will be needed for the life of the engine. The implication I take from that is that the vast majority of the engines should last as long without maintenance or repair, as long as any past Ford engine. From the current history of the SOHC Explorer V6, that is far from the true reality. Make your choice, either run it until it blows, or make an intelligent decision for yourself about when to perform some of these internal maintenance procedures. I don't like what I've read about the great number of failures at relatively low mileage marks of these engines. Good luck,

 

[SICKLER]

bringing this back up top...i have the same noise and everything but i have the 4.6l has anyone else had this problemwith the 4.6 v8?

 

[CDW6212R]

The 4.6 cam timing arrangement is much different from the SOHC 4.0, you should have nothing like the 4.0 issue to worry about. I'd ask either a forum like the Crown Vics, or the dealership. The 4.6 is a pretty good design, other than the small bore large block design. Good luck,

 

[SICKLER]

just got done searching around the crown vic website..and it looks like the rod knock like sound i have could be a tensioner or a plastic chain guide...


http://www.crownvic.us/forum/showthread.php?t=97&highlight=engine+knock

 

[pas06]

We just bought an 02 Explorer yesterday from used car dealer and I am afraid to say that we are hearing this noise also. :-(

 

[SICKLER]

We just bought an 02 Explorer yesterday from used car dealer and I am afraid to say that we are hearing this noise also. :-(

v6 or v8? did u get a warranty??

 

[pas06]

V6...we can still buy an extended warranty but it is through American ....something and I searched them on the web and did not read anything good about them. I am hoping there is a chance the dealership will be kind and giveus a break on labor costs??

 

[Mbrooks420]

Get a hold of C.A.R.S extended warranties. They will warrant any car that is used and recently purchased. I'm not sure how long since purchase you have to be. I spent $750 for a 3 year unlimited mileage warranty, and they had shorter terms. 100 per claim, and they never disputed any repairs, and I had about 6k done in warranty work. Any certified mechanic cold do the work as well.

 

[Mr. Logger]

Yes, I have this TSB from alldata.com but my problem is in paying for the job. Ford does not want to cover it. I don't want to shell out all the bucks and am not not in a mood to pull the engine and do such a major job now. Do you know if the front repair is really feasible without pulling the engine? Per Haynes manual, the engine needs to be pulled.

Thanks,
Tom

It's best to fix it now. I had that same problem on my '02 Mustang GT. Tensioner decided to break when I was 1200 miles from home. Ruined one of the heads, and some of the rod bearings...

 

[pas06]

Get a hold of C.A.R.S extended warranties. They will warrant any car that is used and recently purchased. I'm not sure how long since purchase you have to be. I spent $750 for a 3 year unlimited mileage warranty, and they had shorter terms. 100 per claim, and they never disputed any repairs, and I had about 6k done in warranty work. Any certified mechanic cold do the work as well.

Do you have a number or web address? The dealer tried selling us American Guardian Warranty but I have read allot of bad stuff about them.

 

[pas06]

I just had a local garage order the kit and do the labor of installing it. Dropped the truck off on a MOnday and picked it up Wednesday. The noises are GONE but sometimes it feels like it is getting stuck in first gear and taks up real high. Well minutes of picking up the truck the engine light comes on and I take the truck back..they said the gasket must not be on correctly or somthing like that...and they ordered the gasket and want the truck again on Monday to replace it. I sure hope that everything is fixed right this time.

 

[CDW6212R]

Have them also check the fuel pressure while they have it, a leakage of the high pressure hoses in the tank can affect the engine gradually. I have 55psi maximum, and it should be over 60psi. Good luck,

 

[Mud flinger]

Yep same thing with mine. Did the job myself for under 300.00 took about 8 hours