Finally had a part failure on the old 5.4L

1,140 Views | 13 Replies | Last: 6 days ago by BrazosDog02
BrazosDog02
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AG
After 456,000 miles. I finally had something fail on the motor of the old 2002 F150. Driving to the airport a while back I noticed a wierd tapping noise. I thought for sure that was the clue to rebuild. We limped it back home when we got back and I deduced that it must be the timing chain set that has finally given up the ghost.

So, I toted into it thinking the guides or tensioners had failed.

So off we go…


Nothing weird here other than the guides worn down completely and the tensioners out of adjustment. No excessively loose chains. No matter, we're going to replace this anywhere. It's well past time.



A little beat down on the oil pump, perhaps this is the issue! New oil pump going in because why the hell not. Too many miles to roll the dice.



New timing set. Problem solved.


But not really. After reassembly I fired it up and it was better but not gone. Still rattles way too much to feel good about. So, I figured that maybe the internals are just worn and the oil pressure is to low even with the new pump. At this mileage, it has to be low.




Maybe not. Hot idle finally eventually settled out around 60psi. That's plenty of pressure.



Back in we go but I feel better about dumping more money at it. The only thing left is cam followers and hydraulic lash adjusters.



This seemed to be the ultimate culprit. 16 adjusters, maybe one was still relatively solid. All of the others were totally toasted. Cam lobes looked good, so with a new set, she runs quieter than she has in many years.

We're going to kick this down the road and see how far it will go!

Went ahead and did the steering box with a Blue Top, steering pump to get rid of a whine she has had since we brought it home from the dealer, ball joints, tie rod ends, shocks. Next on the list is replacing a leaking transmission cooler line and the oil pan gasket but I just put new oil in so I'm going to run that for a bit.

This is largely a game for me now. The transmission is still original and I had that rebuilt late last year just because I got nervous. But it was largely OK. I figured at this point, the truck owes me nothing.

If tombs finally dies some day I'm going to see if I can shoehorn a 7.3 Godzilla in it! Probably not.
txyaloo
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That's crazy miles on a stock 5.4. Have you blown any spark plugs out before?

You should get a Lightning intercooler/blower setup and just send it at this point.
BrazosDog02
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txyaloo said:

That's crazy miles on a stock 5.4. Have you blown any spark plugs out before?

You should get a Lightning intercooler/blower setup and just send it at this point.


No spark plug issues to date but when I did the plugs the first time, I used copper anti seize on them.

The only issue I had were some emergency cheap ass Amazon coils I threw on. The coils were fine but the ****ty rubber boots stuck to the wells and I had to dig out ripped plug boots from deep inside. lol.

I like the blower idea.

I had to get a bolt at my local ford dealer and the old parts guy said, I like these old trucks. He had a 1999 7.3 diesel single cab, short bed, 6 speed…or whatever the combo was that was in nice shape.
JB
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About to hit 380k on my 04. Terrible motors!

I think I did the timing set stuff around 260k
BrazosDog02
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JB said:

About to hit 380k on my 04. Terrible motors!

I think I did the timing set stuff around 260k


I know right? Such pieces of *****
Goat Man
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I love reading stories about high mileage vehicles. I wish I had the patience to keep one that long. Thanks for sharing!
HollywoodBQ
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I've only got about 256,000 miles on the 5.4L in my 1999 Expedition.
I had a problem with the transmission slipping a couple years ago at slow speed but, that problem seems to have gone away.

I'm looking forward to getting it back from the paint shop later this month so I can put some more miles on it.
P.H. Dexippus
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If one wanted to have the timing set, oil pump, and cam followers replaced on their old 5.4L 3v by a shop, what do we think a shop would charge in labor? $3-5k? It looks like parts might be in the ballpark of $1200, depending on brand. I haven't removed a timing chain or rocker arms since 11th grade shop class with it isolated on an engine stand, and am afraid I'd do more harm than good trying to DIY it. But there's no sense in dropping $5k into my old truck.
BrazosDog02
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I believe my shop was about $2800 for parts and labor, that did not include the oil pump. I can replace that without taking the pan off, but a shop might want to remove the pan for that job, so whatever parts and labor go with that. I used Ford parts except for the tensioners which were Melling and I think all of the timing parts were under $1000. The book time for the job is about 12 hours if I recall the quote.
BrazosDog02
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HollywoodBQ said:

I've only got about 256,000 miles on the 5.4L in my 1999 Expedition.
I had a problem with the transmission slipping a couple years ago at slow speed but, that problem seems to have gone away.

I'm looking forward to getting it back from the paint shop later this month so I can put some more miles on it.

I love those expeditions. They were SUV built like trucks. I liked the way they rode. I have a 1997 Eddie Bauer 4x4 at my old mans.
JB
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I've got a very intermittent misfire on mine with codes saying stuck rich at the oxygen sensors. Nothing cylinder specific though. I think I've watched a dozen FordTechMakuLoco videos. He is pretty good at diagnosing these but I haven't figured it out yet.
BrazosDog02
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JB said:

I've got a very intermittent misfire on mine with codes saying stuck rich at the oxygen sensors. Nothing cylinder specific though. I think I've watched a dozen FordTechMakuLoco videos. He is pretty good at diagnosing these but I haven't figured it out yet.

What is the code? I assume you have replaced the O2 sensors, or checked for vacuum leaks, and your coils are good?

By the way, for this truck to throw a cylinder misfire, the coils need to be nearly completely failed, or have the misfire be extremely severe. When mine first started nuking coils, I would have to slowly accelerate to 45 mph to let the transmission drop into overdrive so I could lug the engine hard and force that coil to misfire and I had to do that for several miles, three or four times before I finally got a hard code.

I love that guy on youtube. Seriously good stuff.
JB
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Codes:
P2196- O2 stuck rich B1 S1
P0132 - O2 circuit high voltage B1 S1

Issue:
The truck will start running really rough and it feels like a misfire. If i stay in it for a few more seconds, BAM, the issue stops immediately and the trucks goes back to driving fine. It really feels like a loose wire or ground or something that quickly fixes itself. But its also like the timing is way off and then it quickly corrects itself.

Not dependent on speed and doesn't seem dependent on temperature

When truck is driving "fine" I would still say its slightly down on power at least of a 380k miles 22 year old truck.

It seems to idle just a tad low at 600-650rpm, but I'm not sure what it should be

No weird rattling noises like described with yours or like Makuloco seems to address frequently

Parts thrown at it:
-It has 4 new Motorcraft coils and 4 older Motorcraft coils (I just ordered 4 more to replace these)
-Vaccuum line from the intake to the new vapor canister purge valve is new (just a bulk vaccuum line, not the $60 molded part from Ford.)
-Upstream O2s are new (motorcraft)
-Plugs done last year I think

BrazosDog02
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Have you inspected that wiring harness near those o2 sensors? It's good? That low idle feels like a vacuum leak or a hose with a crack in it. I chased a similar issue in mine, but keep in mind is a 2v and a little different. One issue I had like this ended up being the PCV valve of all things. I cleaned it and it didn't fix the issue so I assumed it wasn't the problem. When I ordered parts for another project I tossed in a ford PCV for the truck and for whatever reason, that solved it. It made no sense but I rolled the dice for 7 dollars. The other issue I have had is loose exhaust components. When they rebuilt my trans the didn't get the exhaust back on the manifold tight and it was leaking which causes a condition to be seen at the o2 sensors.

Being able to monitor fuel trims would be handy to identity potential injector issues but I don't know how likely that is.

It's frustrating as hell, I know.
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