So I replaced my phasers, guides,tensioners, chains and solenoids before winter on my 04 crew.
I did an oil change shortly after and it started getting a cold start engine rattle sounding like the lifters going. I never heard it before this so I figured I would have to eventually replace them and this would solve the problem.
It started getting worse so it finally got warm enough out to do it this past weekend and I'm still getting the cold start rattle that sounds like the lifters. It goes away within a few seconds and doesn't come back when warm.
I'm not sure what else it could be any ideas? Should I use a thicker oil, Lucas maybe?

 

What type of oil filter are you using? The motorcraft one has an anti-drainback valve to prevent the oil leaving completely and help to ensure that there is oil present during startup. Also, what parts did you use during the phaser repair? Are you sure that its not an exhaust manifold leak? A small one would close after the engine got hot and would tick when the engine is cold.

 

This sounds like déjà vu Change the oil filter. If it's already motorcraft then change it again with another MC. I just went through this exact same problem. A bad NEW filter was the culprit

Unless you have a cracked exhaust manifold like Vintageman stated.

 

Is it an actual rattle or more of a ticking? I too wonder if you have an exhaust manifold leak.

 

It's not the manifolds, doesn't sound like a manifold leak at all. I have a MC filter and
MC 5-20 syn blend. It doesn't sound like the ticking of the phasers again even tho I did use the Dorman ones unfortunately.
It's only on cold starts it makes the noise sometimes it's a little louder than others. I used an other brand of filter once and it started making the noise so I went to the MC filter and no change.

 

Maybe get a video of the sound and post here for us to help.

 

Try cranking it over for a few seconds with the accelerator floored, then release and allow it to start. Holding the pedal down will put the engine in 'flood clear-out' mode but will also prime the oil up. This should help you to determine if the noise is oil pressure related...

 

I will try that today

 

Ok so I just tried the hold the pedal down and cranked it for a few seconds to build up oil pressure and then let it start and it still made the rattle like the lifters are bad.

 

Would bad solenoids cause this?
Today while I was in a drive thru I heard a ticking at idle when it's only in gear after sitting there for a few min. It went away as soon as I took it out of gear. But when it's running in park or driving it sounds great only thing I hear are the injectors ticking.