Hi everyone,
I had a very small leak coming from the timing chain tensioner bolt (upper passenger side) so i removed the tensioner bolt to add a new ring then installed it back. that's all i did. but now when i start the car it makes clicking noise coming from this side!! what is happening ?

please help

 

Sound like this?

Yeah... it's not good. I'll skip to part 2, 'cause you don't need to see how they pull the engine, where you can see a Ranger 4.0 being taken apart, but what you see there is pretty much what you're looking at, I'm thinking. Look about halfway to see the chunks and bits he winds up pulling out of the oil pan:

Notice especially the chunk that got sucked up into the oil pickup tube. So what happened is the plastic tensioner guide blew up and got sent to the oil pan.

In your case the right side tensioner guide probably exploded due to the stress of being relaxed then retensioned, or the twisting against it as you replaced the tensioner... whatever the reason. 15 year old plastic in a hot engine. It's destiny and things, y'know? You messed with it. Way to go.

And since you said right side... that's engine out. Left side you might can have done it in car, but the jackshaft 4.0 means the timing chain and guides for the right side are up against the firewall, and there's no way to do it... well, you could pull the transmission out and maybe do it that way, but it's not gonna be fun... realistically you'd pull the engine and do it right. And here's part 1 so you can see him explain it:

It's a four part series. This guy is a fantastic Ford tech and teacher. I used his videos on the 4.6/5.4 timing chain situation to rebuild mine. I'd watch all of it front to back, and that way I'd know what's involved and then not have sticker shock when I took it to the shop and they mechanically total the car. Because they will. My 4.6L 3v was 3500 guesstimate (they actually refused to do the work) to replace the timing set, or 6K/9K for an engine replacement depending on what I chose. They realistically put in 4500 as the timing set replacement because 'things'. Understood, of course.

I took it home after paying the diagnostic to be sure what it was, and I did the timing myself as a reclamation project. The engine felt fine, just the timing, so... saw no reason to junk the motor when I can do it. But afterwards.... yeah, they were right to refuse it, by far. It was... fun. So many weird things happened... Still, even so, saved maybe 1000 over the guesstimate. Worth it to me, as the car was technically worth about 3500... to everyone else anyway. She's a million dollar car as far as I'm concerned...

So in your case... honestly, I'm thinking entire timing set while I'm doing it. Maybe new followers and adjusters too because then it'd last the remaining life of the engine.

THAT said... and I don't want to be mean, but reality is not often kind... it's a 2006 Mustang V6. You could literally buy another one for what this will cost if you don't do the work yourself. You do the work yourself? Have all the tools (hence watch that video series!) and knowhow? Want to save it because reasons(tm)? Then it's your project car. Have another to drive while you fix this one, and take your time. Because gotchas and while you're there's happen. Trust me. Or maybe you already know.

Not the news you're looking for, I'm sure. But that's my guess from WAAAYYYYyyy over here. I'll be glad to be wrong, of course! And it could be that it's something else. But if I know where that tensioner is.. which is back of engine, and you get to it from the underside near the battery, right? So what could you have messed up doing that job is the other question... and I don't know of anything else....

I still hope that helps, and oh by the way... Welcome to the forums!

 

You got it all right buddy!
Out of curiosity, do you know if the oil hole in the tensioner must align with the other hole in the block where the tension goes?

 

I'd say it surely should, yes. If there's not a channel for it to be fed from, then alignment is key on that.