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Knock knock....it's NOT a rod!

1997 - 2003 F-150

Knock knock....it's NOT a rod!

  #1  
Old 04-18-2018, 04:43 PM
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Knock knock....it's NOT a rod!

2002 F150 5.4 basically stock. 225K miles. I have recently noticed a lower engine KNOCK??

It does NOT knock ALL the time.. just MOST of the time.
Is prevalent around 1600-2300 rpm, I have NOT been able to powerbrake and DUPLICATE noise?

I currently have the front diff out so I decided to drop the pan and take a look. I even pulled EVERY rod cap ( 1 by 1 of course) and plasti-gauged them....just because nothing felt bad...

Everybody was around the .0015-.0025 range (it is plasti-gauge so....not an exact thing) Doesn't get better than that....so buttoned everything back together.

BUT what else could/should I look at, I'm at a loss here. I would have swore it was a rod but numbers do NOT lie. (btw i am a 30 yr Journeyman Tool & Die maker....ye si know what .001 vs .005 clearance feels like)

any secret squirrel stuff with this 5.4 ..
 
  #2  
Old 04-18-2018, 04:46 PM
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Checeked torque converter bolts, flywheel, exhaust manifold leaks.... all good so far. Even tried pulling 1 plug wire at a time and driving it ....still knock (you can make a knock go quite if you don't fire the cylinder) Removed serp belt...drove it... still knocked
 
  #3  
Old 04-18-2018, 05:30 PM
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Well, if it is serious, it will get worse. Anyway that has been my philosophy about funny noises. Noises are hard to diagnose. I've been fooled many times.
 
  #4  
Old 04-18-2018, 08:19 PM
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Some 5.4's had an issue with piston slap.

https://www.f150online.com/forums/v8...n-summary.html
 
  #5  
Old 04-20-2018, 07:04 AM
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I have heard a piston slap on this truck ....usually only about 5 seconds when its first cranked up...COLD.

anybody got noise stuff about timing chains?....I can't picture a chain making this KNOCK ...but as I have stated....i am baffled.
 
  #6  
Old 04-20-2018, 07:23 AM
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youtube is my friend. By following a dead link in hte piston slap thread....i went to youtube to look for f150 noises...
I may have found my culprit... catalytic converter?

he's a little long winded but...sounds EXACTLY like what I'm hearing. Must figur out how to diagnos.
 
  #7  
Old 04-20-2018, 09:44 AM
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Beat on the converters with a rubber mallet.
 
  #8  
Old 04-29-2018, 11:21 AM
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Finally caught a break.... It was rattling pretty good upon first fire...i crawled under and could actually FEEL the knock INSIDE the front converter on the drivers side...
 
  #9  
Old 04-29-2018, 02:52 PM
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Thanks for letting us know! Glad it wasn't engine mechanical.
 


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