Dreaded Rattle at Idle

[Cruzinit]

Aloha all Sport Track Enthusiasts

I bought my 04 for only 1k, put in about $500 or so for basics. Been putting some miles on it (kids and dogs like it). I wasn't really listening for it but then I heard it, the engine was hot I was going downhill just coasting.

When i got home I busted out the stethoscope. Poking around Yup its in the back passenger side. Depressed I parked it for a week. Today I drove it with the dogs to the post office and back parked idleing facing down hill. Checking again more through for about 20 min. Pretty cool all the stull I can hear with a stethoscope. Injectors, belt pullys, front timing chains (sound good), anyways.

All points to rear timing chain/guides. I have a new valve cover gasket and will be pulling it soon. Hoping its just a timing chain tensioner.
I really really do not want to pull this engine ($1500 dog truck with 300K). Ill update with borescope pics.

My hacking brain thinks there has to be a way to design a "drop down from the top" Rear Cassette guides for almost end of life \ last chance Rear Cassette Ford SOHC 4.0. I started looking for a core to play with today. No good junk yards on the big island of Hawaii though. Updates to Follow

 

[Cruzinit]

Ordered these just in case.
https://www.amazon.com/gp/product/B00WSWV688
https://www.amazon.com/gp/product/B000C2CLBC

Check the pan and filter as well.

Question - Confused if I should prepump up with oil, because it seems I could cause more damage forcing it in pumped up already?

 

[Todd Z]

welcome to planned obsolesce, they don't want you keeping these things....

 

[stunner67]

Aloha all Sport Track Enthusiasts

I bought my 04 for only 1k, put in about $500 or so for basics. Been putting some miles on it (kids and dogs like it). I wasn't really listening for it but then I heard it, the engine was hot I was going downhill just coasting.

When i got home I busted out the stethoscope. Poking around Yup its in the back passenger side. Depressed I parked it for a week. Today I drove it with the dogs to the post office and back parked idleing facing down hill. Checking again more through for about 20 min. Pretty cool all the stull I can hear with a stethoscope. Injectors, belt pullys, front timing chains (sound good), anyways.

All points to rear timing chain/guides. I have a new valve cover gasket and will be pulling it soon. Hoping its just a timing chain tensioner.
I really really do not want to pull this engine ($1500 dog truck with 300K). Ill update with borescope pics.

My hacking brain thinks there has to be a way to design a "drop down from the top" Rear Cassette guides for almost end of life \ last chance Rear Cassette Ford SOHC 4.0. I started looking for a core to play with today. No good junk yards on the big island of Hawaii though. Updates to Follow

There is no way to change any of the timing components or guides on the passenger side without pulling the motor. It's just the way it is with the 4.0 motors. I just did mine. It wasn't too bad. Since the AC line from the compressor goes down below the front of the engine, I was able to unbolt the compressor and lay it off to the side with removing any Freon.

 

[Cruzinit]

Yup

Thats my door code if you happen to be on the Big Island and need to get in my truck

 

[stunner67]

Yup
View attachment 5267
Thats my door code if you happen to be on the Big Island and need to get in my truck
View attachment 5272
View attachment 5269View attachment 5270View attachment 5271

Yep. Now you'll have to pull the motor out to replace that cassette.

 

[Cruzinit]

Test Video Share


294459 Miles OMG

please let me know if it does not work for you.

 

[Cruzinit]

Aloha All Sportrackers - Im not the smartest Rooster in the coop. But here it is about 10 hours over 3 days. I really think there can be a aftermarket temporaory solution if you have my same problem and and your other rear timing guide is still ok, and your SOHC is pretty much at end of life anyways. Better then running it banging the guide bolt. Look away if you cannot stand my hackery. See above video.

I have almost 50 pics and a dozen videos but posting not easy. Anyways....

So I after an hour of trying I could not get this broken piece out. I resighned myself and left it in. PLastic crap, it will clearance it self out (my thoughts)

Video Google - Borescope1

JB Weld Steel Stick - ummmhuh - only the best for this rig

She aint pretty - hopefully she can dance

 

[Cruzinit]

More Hackery - Used the old guide to put pressure on the lower guide. Ohh Yeah Coolaid

Google Video Hackery Guide

Numbers

Oops forgot to tighten the tentioner - lost 2 quarts

The good stuff - Melon Juice

 

[DILLARD000]

More Hackery - Used the old guide to put pressure on the lower guide. Ohh Yeah Coolaid

Google Video Hackery Guide

View attachment 5285
Numbers
View attachment 5286
Oops forgot to tighten the tentioner - lost 2 quarts
View attachment 5287
The good stuff - Melon Juice

View attachment 5288

Keep us updated on how this lasts!

 

[Cruzinit]

Its not my daily driver. Went to the post office and garbage dump a couple times. Went to the beach so far so good.

Tomorrow taking it to Kona town about 120 mile run loaded both ways.
After Ill do a lower pan drop and oil change to see if I see anything. Bringing the AAA card just in case
Updates to follow.

 

[stunner67]

Its not my daily driver. Went to the post office and garbage dump a couple times. Went to the beach so far so good.
View attachment 5303

Tomorrow taking it to Kona town about 120 mile run loaded both ways.
After Ill do a lower pan drop and oil change to see if I see anything. Bringing the AAA card just in case
Updates to follow.

You probably won't see much but smaller pieces. The larger ones get trapped.in the cradle aka upper pan. I strongly suggest planning to pull the motor and replace all the timing components or at least all the cassettes. You can get a timing tools set from Amazon for pretty cheap

 

[Cruzinit]

Dropped the pan at 330 miles, changed oil and filter.

Here are the pieces that made it down. I suspect a lot still in the upper pan.
Id love to pull the motor, I really do but 300K, $1000 truck, hmmm
I have access to 2 more free out of reg dates STs. All same timing issues. Do I really want to drag them to my property?? Hawaii you have to tow/trailer 50 miles and pay 5 cents a pound to dispose of.
But I kinda want to pull a doner motor and cut open the rear casting to see if I can make 1/2 way decent drop down Patch/Fix for people in my same situation. Hmmm

Oil pickup still looks good.

Did another 100 mile run

Recycle computers and UPS, It was actuually quite heavy.

Lumber 70% off at Homedepot, Gotta get it. The rack rocks.Farm Life.

Tires are too big "they look cool" Still seems not 100% power. Maybe timing.

Lots of Fuel, full tank, Walmart Costco and 4 butts in the seats. AC rocked.
Dogs ST did good

 

[stunner67]

Dropped the pan at 330 miles, changed oil and filter.
View attachment 5411
Here are the pieces that made it down. I suspect a lot still in the upper pan.
Id love to pull the motor, I really do but 300K, $1000 truck, hmmm
I have access to 2 more free out of reg dates STs. All same timing issues. Do I really want to drag them to my property?? Hawaii you have to tow/trailer 50 miles and pay 5 cents a pound to dispose of.
But I kinda want to pull a doner motor and cut open the rear casting to see if I can make 1/2 way decent drop down Patch/Fix for people in my same situation. Hmmm

View attachment 5412
Oil pickup still looks good.

View attachment 5413

Did another 100 mile run
View attachment 5414
Recycle computers and UPS, It was actuually quite heavy.

View attachment 5415
Lumber 70% off at Homedepot, Gotta get it. The rack rocks.Farm Life.

Tires are too big "they look cool" Still seems not 100% power. Maybe timing.

View attachment 5416

Lots of Fuel, full tank, Walmart Costco and 4 butts in the seats. AC rocked.
Dogs ST did good

Pulling the motor isn't that hard if you've got an engine hoist and stand. I didn't even have to remove the AC compressor. I just unbolted it and laid it to the side. Saved me money on recover and recharge of Freon. You can get a decent set of timing tools from Amazon for relatively cheap. There is a 4 part detailed video series on YouTube you can follow to do the job complete and correct. Look up Fordmacktechulo. I've done a few of these jobs in my shop and customers always say it was worth it to keep their truck on the road for another 200k miles