I just got back from a short road trip (5hrs) yesterday and when I got back down to city speeds (at a red light), I noticed a loud ticking/tapping coming from the passenger side cylinder bank. It is there whether the engine is hot or cold, and speeds up with engine revs. It is most certainly NOT the normal injector sound that the car has had since new. Wanted to attach a video from under the hood for your review (not sure why it is upside down but you get the picture, or more accurately the sound), but not sure how. Here is a youtube link:


Mods are below. Was running the BAMA 93 torque tune, recently kicked down to 87 torque.

Oil level and pressure are normal. Running 5w-20 Motorcraft semi synthetic with a K&N oil filter. 70K miles.

Any and all info is appreciated.

Allen Sanders
2010 Kona Blue GT
Borla Touring Axle Back Exhaust
C&L CAI
Hurst shifter
FRPP P Springs
GT500 Strut Mounts
Koni Orange all around
Stallion adjustable front sway bar end links

 

I can't watch the video (from work) but first thing I would do is to check your oil...yeah, the oil pressure sounds fine but you might still be low and that sure could cause the clacking.

My 4.6L consumed a bit of oil...supposedly a common issue but that could have caught up with you after your road trip.


Please keep us posted.

EDIT: I just saw that you said pressure AND LEVEL. Oops... sorry.
That would have been an easy fix.

 

Pulled plug on each injector and coil individually, no change in sound. Torqued plugs, all good. Been hitting all the local recommended ford gurus and they all say either lifter, cam phaser, valve lash adjuster. Ran some MOA a few days ago (no change) and about to drop a quart (oil has about 800 miles on it) to be able to add some Marvel Mystery Oil and run for 1000 miles. I've never been a fan of these oil additives but the last ford guy I spoke to swore by it as a detergent to possibly dislodge something that could be causing the problem. He said he would absolutely try it before pulling the valve cover and changing parts.

Thoughts on these two oil additives or in general?

 

Using stethoscope, noise seems to be coming from #3. Gonna give mystery oil a week (if I can stand it) to work it's magic, before disassembly. It might be getting louder. It's DEF getting more aggravating. I don't like strange noises coming from my engine....

 

I pulled the valve cover and immediately saw the problem. The front intake roller rocker (#3 cylinder) bearing had failed, causing the roller to come off its axis. I was able to remove the rocker WITHOUT compressing the valve spring. Luckily it had not previously come out, and bounced around the cylinder head causing additional damage. Top side of rocker had grooves cut in it from the cam slamming into it The cam lobe had a little discoloration, but no scarring that I could feel. Compressed the valve spring and slipped another rocker in, problem solved. Soooo glad I didn't run her any more than I did. Many of the so called ford specialist mechanics told me I would not be causing more damage by running another 1000 or so miles with various engine additives to see if they would free up a stuck lifter (lash adjuster). They were WRONG.

Glad to have my baby tip top again, but not exactly filled with confidence about the remaining 23 roller rockers. Might have a few standing by for the future.

Here are a few pics:




You'll see the failed rocker on the bottom/right, with the grooves cut by the cam lobe visible in the pic of failed rocker on bottom.

 

You mentioned the cam lobe was discolored. Watch it closely for fretting and spauling for a while. There is an outside chance its heat treat and case hardening may have been damaged. I'm not saying it was, but just pay attention to it. If you don't want to pull the rocker box, just keep an ear open, cut your filter to check for steel filings and do oil analysis for a while.

John

 

I fully expect to see metal filings in the filter after seeing how the top of the rocker was ground down. Gonna get that oil out of there sooner than later