My parrents have a 03 explorer 4.0SOHC Flex Fuel. The other day it kicked a ton of misfire codes on bank 1, made a horrible rattling and we smelled burning oil, upon looking at the right rear corner of the valve cover it looks like something impacted it from the inside. I am suspecting that the timing chain cassette broke and sent something into the valve cover, can anyone confirm my suspicions.
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Possible timing chain cassette failure!!!
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DAT05EXPLODER
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anything other than misfire codes?
2000StreetRod
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replacing rear cassette
In order to replace the rear cassette either the engine or the transmission must be removed. It is much easier to work on the engine when it is out of the engine compartment. The SOHC V6 will sometimes throw a cam follower and break the valve cover. If the break in the valve cover is at the very rear then it is probably from a cassette fragment. I suggest that the valve cover be removed and the area be inspected. If the cassette guide assembly is broken but the chain is intact then perform a compression test to check for valve damage. The exhaust valves are usually damaged before the intake valves. If the valves are damaged it may be cheaper to replace the engine than rebuild it.
In order to replace the rear cassette either the engine or the transmission must be removed. It is much easier to work on the engine when it is out of the engine compartment. The SOHC V6 will sometimes throw a cam follower and break the valve cover. If the break in the valve cover is at the very rear then it is probably from a cassette fragment. I suggest that the valve cover be removed and the area be inspected. If the cassette guide assembly is broken but the chain is intact then perform a compression test to check for valve damage. The exhaust valves are usually damaged before the intake valves. If the valves are damaged it may be cheaper to replace the engine than rebuild it.
I pulled all of the plugs on the RH side and used a borescope to inspect the tips of the pistons and did not see any damage so I'm thinking that the valves are ok so I think I'll pull the engine and replace both cassettes and the primary guides as well. Do the cassettes come with the chains and sprockets or do I just reuse the old chain/sprocket as long as there is no damage?
2000StreetRod
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guide assemblies
Did you remove the valve cover to make sure the engine didn't throw a cam follower?
You can no longer purchase just the guide assembly. You have to purchase the entire cassette which consists of the guide assembly, the sprockets and chain. See SOHC V6 Timing Chain Related PNs and SOHC V6 Timing Chain Parts Sources
See My Helpful Threads to learn more about the camshaft timing. Also, if you PM me your email address I'll send you a copy of the Mustang SOHC V6 assembly instructions.
Did you remove the valve cover to make sure the engine didn't throw a cam follower?
You can no longer purchase just the guide assembly. You have to purchase the entire cassette which consists of the guide assembly, the sprockets and chain. See SOHC V6 Timing Chain Related PNs and SOHC V6 Timing Chain Parts Sources
See My Helpful Threads to learn more about the camshaft timing. Also, if you PM me your email address I'll send you a copy of the Mustang SOHC V6 assembly instructions.
I did not pull the valve cover because it was outside, cold, and dark when I did it last night. I will when I get the garage clean and the truck inside. I will send a pm, thanks for your help, I have read most writeups. Anyone know how well that parts from AutoZone hold up? I've usually use parts from there with no problems so...
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