I got the infamous clicking of the timing cassette.

I'm fairly new to this engine, I've had it one year, it has 115k (2010 4.0 sohc) on it. I first heard the click awhile ago, towed it home, and being unfamiliar with this engine I thought it was a bad lifter or something. Pulled the head, got it rebuilt and refinished, replaced, obviously that didn't fix it. Figured out it was the timing cassette, so I pulled the engine and replaced all the timing on it.

After running it a bit, the driver side cassette is still a little loud. obviously better than it was, but I'm not going to run this thing until I know for sure. My only idea left is that it isn't getting enough oil or something? The passenger side is golden. When I took it apart I made sure to clean all the ports, got the one piece of the original cassette out (which was in the sump), so there shouldn't be any other obstructions. Maybe the oil pump needs to be replaced?

I'm out of ideas and I'm sick of throwing money at this thing. Any help would be appreciated.

 

I should add the driver side cassette is barely noticeable at idle, but when I give it throttle it gets louder as the RPM's increase

 

Welcome to the forum

Can't think of any reason the new tensioners didn't fix the issue

The 2005-2011 4.0l SOHC didn't really have this issue, they have the new design long chain tensioners, with any long timing chains there can be problems of course, and with 2, lol, twice the chance of it

The 1997-2003 4.0l SOHC engines were the ones with the old design, but once updated they seem to last

The cassettes were not the issue, but the guides and chains were damaged when the failing tensioners let the chains bang against the guides at start up, which would break them, then the "rattles" started at startup and eventually at mid-RPMs

I have read that 3rd party tensioners could have problems, the Motorcraft tensioners are 3 to 5 times the price, but may be worth it

 

I'm working on my 04 and have been for some time. Do take your time. I've seen back and forth on the issue of whether these 4L V6 SOHC engines are interference or non-interference engines. They are absolutely interference engines. I still have the old pistons that bear the marks of valve faces gouged into them. The timing cassettes on both my PS and DS virtually disintegrated. I had to replace the heads as every valve was bent; And I didn't want to deal with rebuilding them. But in my own research, I have found customer reviews on aftermarket tensioners that bear out RonD's words. Some have reported they lasted from 6 months to almost a year but not quite and not longer (on the negative reviews, which often stacked up). I went to my local Ford dealership and paid more, but it came with a 2 year warranty instead the 1 year most if not all of the others come with. You don't want to end up in my situation. It's expensive. And frustrating. So take your time and research, research, research. And then double check. lol Best of luck!

 

Will the VIN# tell if the engine is SOHC?

 

Yes, 8th digit of VIN is the engine code
X = 4.0l OHV, 1990-2000, Ranger or Mazda B4000
E = 4.0l SOHC, 2001-2011, Ranger or Mazda B4000

Explorer used E as well but also K for a Flex Fuel version of the 4.0l SOHC

 

That is great info RonD. Is there a chart explaining VIN codes on the various model trucks and engines?

 

Yes, have a look here: https://en.wikibooks.org/wiki/Vehicl...Ford/VIN_Codes

Cars and trucks use different engine VIN numbers, so there are two charts
i.e. X in a Mustang is a 4.6l V8 engine, in Light truck its 4.0l OHV, during same years

 

Do not!! Do not!! And I mean Do not!! Get the cheaper aftermarket tensioners. Take it from me I'm working on pulling my 03 4.0 sohc engine out for the 3rd time in about a year and a half all because the first time after 245.000mi which was not bad I had to replace the timing chain components but I ordered on eBay and after 12 months I had to pull engine out again .and replace them. And stupid me for wanting a quick and cheap fix I bought from eBay and after a week rear chain broke after i was told due to failing tensioner. So when it comes to these engines spend the extra money because if those things go bad engine has to come out!! Hope this helps!.