After verifying everything was tight, times and aligned I did a few revolutions to check... and both chains are not 4 links off. I will take it apart and reset - what went wrong? What to check?

 

I hope you do realize it takes something like 122 revolutions for the chains to be aligned with the timing marks again. Since you did a few turns, they're going to be off. Also, the crank rotates twice for each turn of the cam shaft.

As long as they were aligned when you set it up (two over the left/right marks (R is up for passenger/L is up for drivers side), one under the dot on the crank sprocket), you are done. There was no need to rotate to check.

 

Wait - what? Cam sprockets are keyed to camshaft. The chains keep crank ( and sprocket) in sync. Every 2 revolutions of the crank everything should be back in the EXACT same alignment. It MUST repeat every 2 revs is how I understand it... what am I missing?

 

I realigned chains and marks, rotated agai . Same result. I just do not understand. Everything rotates fine so should not be damage if started but a lot of work to go back thru if I f#$@ ed it up.

 

Its a mathematical thing ---- "the least multiple". Before you tear it down again, it would help if you read through this rather lengthy post.

https://www.f150forum.com/f4/final-r...3/#post4475795

 

Thanks for the education and some peace of mind. I'll button it up. I was way over simplifying things in my thinking.

 

You're not alone. Ford didn't go out of their way to make it simple.

 

Yeah, you were over thinking it. I don't think I even knew about that thread, but mostly I just remembered what @F150Torqued had constantly said to others that the marks on the cams, crank and chain are aligned every 122 revolutions that once I had put the chains on and it was all aligned, I didn't bother trying to turn the engine to check (In fact, I didn't even think about it). I only rotated the crank to reinstall the roller followers (that alone took a few revolutions to do)

 

Thanks to everyone for your help. I finally got it buttoned up. Everything seems fine. No leaks, rattles etc. Runs pretty well - with the exception of a slight stumble/rough idle w/ AC on. I also changed all the fuel injectors (Motorcraft)and all 4 O2 sensors (Bosch). Not very rough - just a little "unsmooth" - very slight but noticeably different w/ AC on and off. AC off is very smooth, AC on has a little roughness....

What would cause the lumpy idle? Dirty MAF or TPS ? Not sure what else...

 

My truck has a slight roughness to it at idle after I did my timing. My guess is I didn't use enough gasket maker at the points it was required (not a perfect seal). Otherwise, it runs great driving around and has lots of power.

I do have a set of 24lb Ford racing injectors (the six hole) sitting around, I've just been too timid to try these out (2005 and 2006 model years have two hole injectors). I'm too worried about getting a rich code from these. Supposedly, I could see a 10% improvement in fuel economy if I do install them. I do have the updated throttle position sensor, but haven't installed it yet, since the original is working fine. Also never cleaned the throttle body when I did my timing.