My 04 5.4L has been making some noticable ticking from the engine. It sounds like spark knock usually. Today, however, I opened the hood and listened and the sound is coming from the top end (cam) it sounds like a ratchet just spinning. only have 35k on truck, but warranty is expired by years. was there a recall on this year and engine. How should I approach the dealer. I've heard this a common problem, and others have had it fixed for free.

 

From what I found out. I was told it is not a problem and would not hurt the motor. They were fixing some under the new car warranty, but if you have the extended warranty, they will not cover it unless they fail during the warranty period.

 

I also have an 04 5.4L, and I experienced the cam phaser knock as well. You'll know if it's the cam phaser for sure if you only hear it at idle once the truck has reached operating temperature. If you can hear it all the time, it's something else.

As for the warranty, the replacement of both of mine were covered, but I was still in my warranty period. You may be able to get the dealership to fix it for you out of warranty anyway because it is such a common problem. THe cost of it out of warranty would have been $450 parts and labor (for one side).

Pkurek is right, it won't hurt the motor at all if you don't replace them, it's just annoying as hell when you truck sounds like a diesel at every stoplight...

 

Guys, go hear and watch the Ford Tech video episode 22 to see how Ford looks at Cam Phaser noise. http://www.flatratetech.com/index.php?categoryid=4

 

I just read the TSB 06-19-8 on the Cam phaser noise. It's probably the cam phaser for me. At hot idle you can here a ratchet noise.

 

The cam phaser is normally a knock, a ticking sound is the injectors.

 

X2

It's a clear knock, not a ratchet or tick.