Dealer I bought from said my engine ticking and knocking was normal. Went to a second dealer and just got truck back from that dealer that has had it in shop since middle of last week. Replaced right cam phaser and all lifters. Replaced all 8 plugs since 4 broke during removal and had to pull heads to get the broken ones out. Sounds much better but they said there is still the "thump" mentioned in TSB 06-4-7 which they gave me a copy of. They said that noise is normal and has no fix. Looks like 15 hours labor if I read the service report correctly and page long list of parts. All warranty work and glad I didn't have to pay a penny. (If they had this much trouble with my plugs at 33,000 miles what is in store for folks at the recommend normal replacement of 100,000 miles?) Without this site I would never had known of this problem and what to listen for. I probably just would listened to the dealer I bought it from just tell me everything was normal. This second dealer took care of my truck and did it promptly. They called every day to let me know what they were doing and I just said to take the time to do it right. They also solved my dash rattle which was a loose sensor that hangs on the rear view mirror. So now I have a letter to write to the first dealer on their diagnosis, or lack of it. I probably will start out by telling them I may never buy from them again, definately will not depend on their service dept, and I will be sure to tell everybody about this experience with them. Anything else I should tell them?

 

Just curious, what gas did you usually run? A brand name or independent, and did you run a fuel injector cleaner occasionally? Wondering if you did these things and still had the plug problem.

 

Wow..

 

I use any gas and have not used any injector cleaner. I have known about this ticking/knocking problem for 2 years by reading this site. So I don't think gas or injector cleaner use would have been an important factor with my truck new 2 years ago. Previous posts on this site reported mixed success and suggested waiting until Ford had a fix that was proven to work. So I waited to get serious and get it fixed while still under warranty. That is exactly what I told the service advisor, service manager, and engine tech. as we huddled around my truck listening for noises. They sort of nodded and got down to business, mentioned TSB(s) and a known problem with this engine, ordered parts, and took care of my truck..

 

I agree about gas and cleaner not having anything to do with the cam phaser, just the plugs. It has been suggested that running fuel with cleaners and doing the recommended injector cleaner additive, it might keep the carbon build up from happening on the plugs. That was why I was asking.

 

Bkuejay...
I see your point. Dealer I bought from once told me do injector clean at 45,000 miles, but I don't know about their recommendations anymore. Second dealer that did the work said plugs looked ok - but I'll bet the 4 broken ones looked pretty sorry. I was not focusing on plug issues when I took it in because I have been aware of noises since the truck was new. I do understand plugs can be a factor with noise with these engines - guess I learned that reading here too.

 

Just curious, what dealer finally did the work. I am in WI also...I have a fairly loud tick I know to be the cam phasers, but my dealer, (Hiller) said everything is normal....Mike

 

Mikedom;
Kayser Ford in Madison fixed mine

 

It's not carbon on the plugs that's getting them stuck in the head, it's rust forming around the insert portion and reacting to the aluminum in the cylinder head.

 

what's a cam phasor?

A friend of mine just picked up a brand new 06 lariat and it has had a ticking noise since she picked it up. Kinda sounds like an exhaust tick...? same thing maybe?

 

There is a normal light ticking that comes from the injector system. The cam phaser tick is much louder.

 

Yes, like the above poster stated, the cam phaser knock is louder then a tick, it sounds like an engine knock, like someone is hitting your block with a rubber mallet.

 

Quinton:
Do I remember correctly that you are a service manager? I've read lots of your replies in the last year and you do know your stuff. So how can Ford engineer or mis-engineer a plug problem like this. Is there any cure? Does antisieze help?

 

Did they replace your plugs under warranty after they broke or what? Im dreading changing my plugs, hopefully I will trade it before it needs it.

Its sad that vehicle quality has gone down this much.

 

Funny, I looked at my plugs after the tech took them out (TSB for spark knock) and they looked fine, no problems coming out. He said there were no problems whatsoever.