2005 developed loud engine knock

[Uberexpy]

The roller follower on the left was the culprit. The cam lobe it rode on had some false brinelling with metal transfer to the lobe from the seized bearing. I put the cam on a lathe and polished out the pits. I only lost 0.001” of lift. I can live with that.

 

[Uberexpy]

Another view of the worn roller followers

 

[JExpedition07]

I did mine in April, I used a new Ford OEM oil pump along with the rest of the OEM stuff. (I’m the only guy I’ve seen do this AT ALL lol). Everyone else uses the Melling. So far no issues with the new stock Ford parts. A blown out tensioner was my only symptom, a startup rattle. Valvetrain was still in good shape in my case.

 

[JExpedition07]

This was my startup rattle. These tend to start a dominoe effect

 

[Hotrod]

No that was a long block, what a joke I said.

 

[mfdbackdraft]

Well got the bad news, technician says the knock is diagnosed as internal and likely in the block not the valve train, they quote new engine at $9,300.....LOL. Not sure I buy this diagnosis considering how well it runs and no codes. But looking like it's time to replace. Would hate to do a timing job then still have the knock.

Appears all the new Expy's have the 3.5 twin turbo, questioning the lifespan of the turbos and motor with the high pressures they run.

 

[mfdbackdraft]

Im in same boat. Change the 3.5 oil religiously as well, and read up on adding a filter for the ¿EGR gasses?. Hi temps and turbo pressure puts a lot of 'stuff' in the EGR pathway

 

[Sam wiede]

Wow! My 06 5.4 Exped with only 102,000 miles and previously running strong is now at the dealer with a very similar problem. Number five and number seven cylinders misfiring, and all the related codes. Technician/service rep quoted $4000 repair estimate. Ouch! I’m now waiting on parts and have been told some parts have been known to take 2 to 3weeks to get due to COVID-19 etc. etc.

On the bright side they gave me a 2020 expedition max as a loaner. Wow! What a machine! I think I’ll ask if they’ll trade me Even Steven. What’s my odds?

 

[Hamfisted]

Honestly I'm not surprised there hasn't been a class action suit against Ford for the replacement of the early 3V motors. They were garbage and caused the majority of owners so much money and heartache.