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Loud rattle on cold start up

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Old Aug 31, 2025
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From: Mesa, AZ
Loud rattle on cold start up

2004 Ranger, 4.0L SOHC, AT, AC, PB, PS, PW, 4X2, extended cab, 234,200+ miles

Complete timing system replaced 62k miles ago.
Loud rattle on cold start-up. Sounds like possible timing chain rattle against timing cover. Is it possible one or both tensioners have failed?

 
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Old Aug 31, 2025
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From: PSL FL
Any thing is possible. When you had the chain replaced did you also replace the tensioners?
 
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Old Aug 31, 2025
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From: Mesa, AZ
Yes.
Actually, I paid a shop $4k to do the work. They replaced all the timing components, resealed t he engine and more.

I am wondering if I should try replacing just the tensioners as they are accessible without having to disassemble most of the engine or removing it from the vehicle.
Also, I would think slack in the chain(s) on start up could damage the plastic guides. That would not be good.
 
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Old Sep 2, 2025
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From: Mesa, AZ
UPDATE:
This rattle was definitely the right side timing chain tensioner.
The shop that performed the timing chain work 62k mikes ago, insisted that they use Cloyes parts and components. I replaced this tensioner with a Ford part purchased from a local Ford dealership and had to obtain the gasket for the same from a different local dealership.
The right side unit is easily accessed by removing the front tire and inner fender well.
BTW, the Ford "gasket" for the right side tensioner is a very thin steel "warped washer" type and costs $10.27. And it does make a difference and does it does seal - please don't ask me how I know this.
The removed Cloyes unit had a much thicker aluminum crush washer for a seal. As there is an oil port at the very top of the tensioner just barely below the underside of the flange nut, I wonder if the aluminum crush washer may have restricted the oil flow and in doing so did not allow the tensioner to fully extend and maintain adequate pressure on the timing chain cassette?

Anyway, problem solved!
 
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