I don't know if this is old news to you guys, but, I just got word from my dealer that they are no longer replacing the 5.4s with piston slap. They say that it does not effect long term durability of the engine.**coughbullsh..cough** Unfortunately mine is getting progressively worse with only 45,000km to date on it. I did bring it in to them the first year I had it, but they turned a deaf ear to it. I think I'm going to demand a brand new 2002 engine be installed, and see where that leads me.

 

Make a call to the Ford Customer Service Center and voice your concern. If you call enough they are going to get sick of hearing from you...Just be calm when you are talking to them, and you might get a better response. Just an idea.

 

Looks like I might just have to call Ford customer service. After the service guys started my truck up this morning, they called me back reporting that they still could not here any problems. Just before I drove it to the dealer the night before, it was knocking. Deny deny deny, that's all they do! Why can one dealer diagnose the piston slap, and the other can not? This is really pissing me off! There going to keep it there one more night, and start it in the morning. For there sake, I hope they hear it!

 

fordification,

the dealer didn't hear my engine until I was standing there when they started it in the morning. It was not even very bad that morning, but my being there was all it took.

Good Luck,

 

fordification

Here is an idea that I used for my wife when here car service dept. gave her the run-a-round. I used my camcorded and recorded the sounds and sights (smoke out the tailpipe). She took her car in several time because of very hard starting and when it did start a cloud of white smoke shot out the tail pipe. The service folks kept saying they had no problems starting it. Asked her if she was pumping the gas, etc....

When I went in with her they started the say deny line....out comes my camera and ask for the service manager. I showed him the tape and he knew right away what the problem was even without looking at the car. two hours later she had a new fuel pressure reg. and a smile.

EVIDENCE! Put it in their face if you have to!

 

There only open week days, so I'd have to charge them a days pay if I go down there. I do have a camcorder. It would have saved alot of time if I did just record the knocking. We'll see what they say this morning. Otherwise I'll be talking to the foremen, then Ford, then the Better Business Bureau for a claim.

 

Yeah, that's a big no go for the diagnosing. They still deny hearing anything. They say that the piston slap described from Ford is alot louder, and what I'm hearing is normal. Looks like it's time to get a lawsuit going.

 

By law they have to replace it if it is defective.

 

What actually causes this SLAP. I've got a 99 5.4 and no noises noticed yet in 35,000 miles

 

Went into the dealer this morning. He doesn't deny that there isn't a noise, but he says the 5.4s are designed with a loose tolerance, which would cause what I'm hearing, and that Ford is still calling this normal at this time. He then gave me the number to a service rep. to tell them that the noise I'm hearing isn't normal. Basically he just past the buck. I wish I went in there a little more pissed off to make a statement but I'm kind of tired today. It also didn't seem to be as loud today, even by putting it in drive and loading up the engine. It's only a matter of time before it gets worse.

Rick99, I'm pretty sure it's caused from the piston having to shallow of a skirt. The skirt is designed to center the piston in the cylinder, and when the skirt is to short(cue Raoul), the piston tends to rock in the bore on cold starts. I pretty sure it's mostly for the Windsor engines and only some Romeo's built from 97 to mid 99's.

 

Took my 2000 F150 5.4l 4x4 truck into the Dealer overnight. They started and said the engine noise (Piston Slap) was normal. I went down to the dealer and started it in front on the service manager. I showed him the noise and he went back to talk to the mechanic. The ended up saying that the noise was normal. Ha!Ha! not normal.
I call the Ford 1-800 normal. I spent almost and hour on the phone with them. The said that Ford stopped replacing the motors because their engineers said that there were no engine wear problems assocated with the ps and that this would not cause an engine breakdown.
Now I am stuck with a Piston Slappy 5.4l engine that leaks oil from the passenger head gasket with 78,000miles.
I don't call that Ford Customer Satisfaction .

 

Yeah, where is exactly is the "Quality Care"? Obviously the qualitiy isn't there, and they really couldn't care less about the problems. I didn't think there was any piston slap problems with the 00's. Any mechanical noise is bad unless it's a diesel. Not one single gas engine is designed with a knock, and nobody in there right mind can think that it's "normal". Back in the early 90's, all the 3.8s were replaced because of a similiar piston problem. The longer they hold out, the worse Ford's image gets. Cause if your loyal customers that are buying the products aren't satisfied, what other consumers are there? Everybody I know that are loyal to Ford are aware of all the problems I've been having, and now there reconsidering there choice.

Does anyone have an e-mail address for Ford customer support in Canada? I think I'll e-mail then every other day. And when they reply, I'll increase it to everyday till they cave.

 

u are sure its the piston slap? does it sound like a grunt when u first start the engine in the morning? (ac noise) make sure all switches are off and once it gets colder listen again, if its there a person should be able to hear it. Its also a good idea to start it with the fan belt off as a bad belt or tensioner can make the same kind of noise. (missing rib on belt, stretched belt causing tensioner to hit stop, tensioer bushing, etc)

Btw my truck has the piston slap and i could have got an fqr but i decided to keep what i have, doesnt burn oil but it does have a rattle when cold, they have made past 180,000k with rattles (buddy has a 97 5.4, still runs running)

BTW chev's rattle too but they wont replace the engine, ford atleast does, but they have to verify the noise first as a lot of people have heared of this problem and just figure they will get a " new " engine , u would be suprised how many people complain of the noise at 58,000 km just because they want a " new engine ", not saying that you are I'm just saying that some people ruin it for all of us by wanting problems fixed that aren't there.

Btw i've seen 5.4 with over 200,000km and the customer thought the engine noise was cam chain rattleing and wanted the timming chains replaced - it only cost him a $5 pcv valve and half and hour labour - and believe me it sounded like a posible cahin noise except that it was commig from the pass side valve cover area, seen it on crown vic's too so as you can see a verfication is a must before a $5500 engine can be replaced.

If the noise can be verified then they will more than likely replace it, that is if you choose to have it done.

A lot of people bad mouth ford but what do u expect them to do if they can't hear the concern? Its a known concern but I'd wouldn't be supprised about the number of engine's needlessly being replaced just because the customer wants a new engine or for some other problem that wasn't actually the engine - again I'm not saying you are I'm just trying to help show you why the concern must be verified

Its also a good idea to change your oil every 5,000km or less - not saying this will fix it all i'm saying is its a good idea and a lot of people don't

 

The 5.4 gets a bad rap but its actually a good engine design and probably the best of the 3 modular motors just has some stupid problems like head gasket leak (dont see it much now, never had a v10 with a leak but have had 4.6 romeo and windsors)

These are still relativly new engines and most of the problems have been taken care of and they do have a good design, pain to work on but still a good strong design - generally only seen the 5.4 replaced for piston slap or continued head gasket leak, never complete failure

BTW mine is a 99 (built in 98), head gasket leak before 5,000km , head gasket replaced - hasnt leaked since and now at over 50,000km, piston slap - didnt want fqr - slapped since new - one of the first with slap and head oil leak - still running fine on original engine and probably will for a long time to come

 

Just to throw in some balance.......

I have a 2000 5.4 in my 2000 Expy (of course) built in Oct 2000. Runs like a champ, no noises, I'm happy as can be!!