2002 F-150 4.6L 2V REP (Romeo). When replacing valve covers, I noticed slack in chain on Passenger side so I decided to replace timing components. After replacing with MELL Gear kit including cast iron tensioners, I hear a knocking on passenger side. Here's the rub... I realized after installing tensioners and pulling the pin that my colored chain link was not lined up to the timing dot on the crankshaft sprocket, so I removed tensioners and chain. This caused the tensioner to fully extend so I had to play with it to figure out how to reset it to initial position and get the pin back in. In doing so, the whole thing sprung apart. In reassembling, I did not see or realize there was a little plastic disc that covers the oil hole in the plunger until after the job was done (if you're unfamiliar with this, see this link https://stangnet.com/mustang-forums/...e-look.851114/). Obviously my tensioner is now defective and I plan to tear it apart and put the disc back in. My question is: do you believe this could be the cause of the knocking? Or should I be looking elsewhere? Thanks.

 

Yeah, sounds like a teardown, replace the tensioner and check everything is what you need to do. We've all had to do things twice before too.

 

Sorry this happened, that's a big job to do twice. I just did my timing chain and I know. The video told me check everything three times before pulling the pins out of the tensioners. I'm glad I did, I had one of the lower chain sprockets on backwards and the chains would have rubbed into each other. I also triple checked the marks, it's very easy to jump a tooth before pulling the pins. My truck also started knocking after the job so I don't know if the plastic disc will fix your problem. I also have chain noise for the first 2 minutes after starting.

 

Well that was it! That little plastic disc back where it belongs made all the difference.

Second time wasn't nearly as bad... didn't even need the video this time!