Worn Timing Chain Cassettes May Cause Rattling Noise From Engine on Ford Explorer

A rattling noise from the engine may indicate that the timing chain cassette is worn. Our technicians tell us that installing an updated cassette and timing chain tensioner should correct this concern.

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Average mileage: 130,070 (13,000–220,000)
Engines affected: 4.0L V6, 4.0L V6 SOHC, 4.6L V8
10 model years affected: 1996, 1997, 1998, 1999, more2000, 2001, 2002, 2003, 2004, 2010
90 people reported this problem
48 people shared problem details
A year ago I had the upper and lower intake, the plenum and head gaskets replaced. There was a slight rattle and was told it was a heat shield on my exhaust close to the manifold that had a broken weld and was rattling,I already knew this to be true I had found it doing an oil change. The mechanic removed the heat shield hence removing the rattle only there is one huge problem the rattle didn't go away but got worse. It is so loud now that my V6 sounds like a diesel while idling and even worse when accelerating, HELP!
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2004 Ford Explorer- 4.0L V6 SOHC141,000
Noisy timing chain tension adjusters and has not been repaired yet. Looking for economical solution.
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2004 Ford Explorer- 4.0L V6 SOHC121,000
Rattle noise at cold start is becoming more apparent most of the time.
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2000 Ford Explorer- 4.0L V6 SOHC110,000
Rear timing chain cassette was broken causing rattling noise, engine had to be removed in order to repair it.
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2003 Ford Explorer- 4.0L V6 SOHC160,000
all 3 timing chain cassettes broke causing all 3 camshafts to jump time.it bent 5 valves I had to have engine removed for repair( r. side timing chain cassette can only be accessed from inside bellhousing flange!)also had to have auxilliary shaft brgs. replaced because the front 1 had spun into the engine resulting in sudden loss of oil pressure.my mechanic said "this engine must have been designed by aliens!" it is actually designed by, Ford of Germany. there goes my faith in Ford delivering a well designed &built product!
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2002 Ford Explorer- 4.0L V6146,000
valves rattlin like it lost its oil preasure
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started hearing a rattling noise one day.the rear timing chain snapped and came through the valve cover.apparently this is a common problem with these motors.a friend of mine had this happen to both of his 04 explorers,and its the biggest problem i find on every forum. .it was pretty easy to diagnose the problem since about 5 inches of chain was sticking out of the cover and oil was everywhere.i currently have the motor out of the car (which you have to do to replace the rear timing chain).
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2000 Ford Explorer- 4.0L V693,000
Ford XLT Explorer. My mechanic removed the oil filler cap to listen to the sound coming from the right side front of the motor. It sounded like the clicking of a diesel near where my power steering pump is located. This problem seems to be intermittent. It was not there on a cold start so I left and drove a short way; parked for about 15 minutes. Upon restart, there it was. It's his opinion that a timing chain nylon tensioner on the front is either worn or gone entirely causing the chain to slap the sides or the another chain that is near it. It takes special tools for this so he recommended I take it to Mountain View Ford in Chattanooga to diagnose and repair. Carl
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2004 Ford Explorer- 4.0L V6101,000
Rattle coming from engine almost sounds like a bad valve.
Small rattling noise turned into timing chain broke cover and lost all oil out of top of motor
2002 Ford Explorer- 4.6L V842,000
rattleing noise on acceleration until shifts into overdrive an then noise stops
2010 Ford Explorer- 4.0L V6 SOHC60,113
The engine was running perectly when all of a sudden it started misfiring and check engine light began to flash. Ford Dealer said timing chain jumped bent a few valves, broke apart and pieces fell down into the internal engine. Also said this has been an ongoing problem for years.. Dealer said approximately $10,000 to repar... YES "$10,000" is the exact number he quoated me. My warranty is 60,000 miles I am 113 mile over the warranty and FORD refuses to do anything for me. Let me repeat that ONLY 113 miles over the warranty. This is my third EXPLORER and I'be been a Ford Buyer for Many Many years. FORD SAID "SORRY HAVE A NICE DAY!" I will NEVER BUY ANOTHER FORD PRODUCT.. and I will tell EVERYBODY about how FORD treated me..!! Going to look at Chevy Truck today !
2002 Ford Explorer- 4.6L V8170,000
Drives like the day I purchased except for the rattle of the timing chain guide/cassette. Oh and the cracks in the rear hatch that was fixed three times under recall/service bull then Ford decided they were done with it.
2003 Ford Explorer- 4.0L V6 SOHC168,000
I've had this problem for awhile maybe 15k. The car rattled from the rear cassette when I didn't change the oil for maybe 5-6k mi. From what I understand it's a plastic piece and breaks down over time. After a few changes of oil and time the rattle has lessened. I did seafoam it with seemingly no change. I can't say for sure that my actions have corrected the problem but it hasn't caused any further problems other than my own peace of mind the cassette will fully break and damage internal components.
1998 Ford Explorer- 4.0L V6151,156
Rattling noise from engine
1998 Ford Explorer- 4.0L V6119,000
hasn't been fixed want to get it fixed
1997 Ford Explorer- 4.0L V675,000
Cassettes broke at 75.000. Had engine rebuilt with newer timing chain parts. Engine died again at 130,000. Junked explorer. Plastic and timing chains do not mix. Hey Ford!, why not a gear drive for the cams? Jeez.
2002 Ford Explorer- 4.0L V6 SOHC13,000
noise above 2000 rpm under load
2003 Ford Explorer- 4.0L V6 SOHC204,000
Rattling - worse at idle when normal temp...noise lessend as rpm is increased. Waiting for solution on Forum
1996 Ford Explorer- 4.0L V6126,000
SOHC timing chain guides broke. Interference engine died. All boneyard replacements had same issue. Junked the truck.
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