Hi All!

Thanks so much for participating in this forum. In just 1.5 years I understand a lot about my 2004 5.4L 3v powerhouse and am not scared to tackle anything! Recently gotten on top of stalling issues - cleaned throttle body and new gas purge valve solenoid cleaned that up. Intermittent starts and starter spinning without engaging - cleaned key cylinder and new starter. Driving down the road and get a front end grinding - check valves on IWE system line and of course updated solenoid with rain hat. New VCT solenoids with updated design. New wiper cowels. New fuel pump driver module. New fuel filter and even my own oil changes. Misfires? - defn not tranny but sure was COP. All done meself thanks to your kindness and education!

Truck is running good, so good. 12-14mpgs in town, up to 17 mpgs on highway. Just changed the oil - no glitter or plastic. Have some intermittent startup rattle but think its the phaser or some wheel pulleys - get no chain noise and the sound often sounds like lifters right after oil change so not too worried about timing stuff yet.

Now - have the cam phaser knock at hot idle (used to be Dad's truck and he said always had it). Knock goes away above 1200 rpm like Ford TSB says. Absolutely no drivability issues or CELs (at least after fixing the stalling problems). Definitely not exhaust leak/manifold issue. Just the typical cam phaser knock at hot idle.

What point would you recommend tackling the cam phasers? Since I can't confirm that timing components need fixed yet figure I just drive on until get chain noise at startup or CELs and loss of power? Been having trouble in MT trying to find a mechanic who would like to work inside this engine - no trouble finding many that won't touch it! Thanks for your thoughts.

 

Hey Stavros. 2 things I would suggest. First would be to check your oil pressure. Ford spec is now 15 psi, but you expect to be in the twenties. I have an OTC kit for this that I'm happy with. I would order another oil pressure sensor to have one on hand in case you need it. The other would be to get TorquePro to monitor your pids and look for pending codes. All you need for this is the $5 app and a bt or wifi ODBII adapter for as little as $10.
If you are able to confirm an issue, plan on repairing asap.
Sounds like you are breathing some life into that '04! How many miles you got? I had my '04 up to 19 mpg hwy until I added 2' lift in front..

 

Phaser knock is of no concern. Regardless of proper oil pressure or not, the locking pin inside the phaser is a wear item and will start knocking eventually. However it doe not pose any threat to the engine. If you start getting an obvious chain rattle against the guides on startup. replace the timing set. Otherwise she's safe to run

 

Thanks for the response: got TorquePro and a ODBII reader. I get an occasional B1352 'key in error' but other than that no codes are thrown! :-D. Oil pressure testing may be beyond me. Can you send a link to the tool you have (e.g. Amazon)?

Yes - getting some life from the old girl at 162K miles. The stalling issue was annoying for about a year but thanks to this site I have a clean throttle body and new fuel canister purge valve. No more stalls, idles nice.

 

Thanks - was hoping to hear someone say that the knock is OK as long as she runs good. Sometime quick rattle at start but its not obvious chain noise, sounds more like pulleys or the quick tap-tap-tap that happens right after an oil change. I've listened to a bunch of 5.4l and 3.5l chain noise vids on youtube and its definitely not there yet. Plan on driving it till she shows worse symptoms...thanks!

 

That's great! Now it's time to start moddin' haha. Did you get your misfires taken care of?

 

Thanks for the link.

Yes - misfires due to bad cops, replaced. Swore it was tranny shudder but the dealership I went to was good in this regard and educated me...

 

With the phasers knocking, the bigger question is why: most likely low oil pressure, probably from weeping tensioner seals. Foregoing this can be catastrophic. I lived with "only" the knock for almost 10k miles until I started to notice a slight startup rattle (I'm the only person that could hear it; the Ford techs as 2 dealerships couldn't), and on disassembly noticed that an entire chain guide was GONE. Start saving the $$ and do the job right once, and not twice. If you've got a gas engine that idles like a diesel, it's time to start preparing.

 

Thanks for the comments. This truck has 162K miles, used to be Dad's and he stated that its had the hot idle knock as long as he can remember (bought it new). I'm betting that its just the phaser locking pin that wore early on. The chain/startup rattles are apparent nor happen at every cold start. I get an intermittent rattle at cold start, not too frequent, but sounds more like the taps of lifters after oil change than does chain burrrppp. Until she starts rough idle or throwing codes think it may be good to go? Absolutely no run issues...

 

one thing I would do is run some 10w 40 with some lucas oil stabilizer and it might possibly clear up your little rattle and then you can listen for any big rattles later where you from in MT by the way i'm originally from wilsall in the Bozeman area