2003 Ford Expedition 5.4 2valve engine Noise

[Martin Lopez]

Hi, can you give me your advice on this problem no engine code no vacuum leak no coolant leak and a new Pcv valve. I did replace the intake manifold 5 years ago with the Dorman part. I hear the sound at 2000 to 2100 rpm. The new intake has Approximately 30,000 miles. Thank you for your time and all you do to inform ford Owner.
https://youtu.be/4vrCdNlL1RE
Sent from my iP

 

[Hamfisted]

How many miles on the motor ? Sounds like early timing chain slap to me....

 

[Martin Lopez]

It’s has 137,000 the sound is coming from the top of the intake manifold

 

[Hamfisted]

Oh, Ok. Can you take the serpentine belt off and run it for a minute and see if the sound goes away ? Maybe the alternator bearing failing ?

 

[Martin Lopez]

That’s what I thought at one point so I took off the serpentine belt and started the engine and got the same noise.

 

[Martin Lopez]

I was doing some more research on the intake manifold from dorman and I was thinking maybe something came loose from the baffle? Have you heard any issues with the aftermarket intake manifold from your experience?

 

[Hamfisted]

I know the Dormans use thinner plastic, but that specific noise I'm not sure. If you want to replace it with a Motorcraft part they're still available. You can try spraying some carb cleaner into the intake inlet while it's running in that rpm range and see if the tone changes with the noise.

Ford 5.4 Motorcraft Intake Manifold 2L1Z-9424-AA






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[Vincent Vega]

You said it was coming from the manifold/throttle body area - Maybe the EGR or something like that came loose and is rattling? A plugged cat backflowing into the EGR could make weird noises. In the video Your timing does sound loud so like Hamfisted said, might be a timing or top end problem. A loose baffle isn't impossible but I have never heard of that happening. You could take a stethoscope and see if that guides you to the problem - I would place it over the valve covers and timing cover first to see if it is a timing issue.

 

[Martin Lopez]

Thank you all for the input looks like I have some homework

 

[Vincent Vega]

Looks like you pulled the throttle body. Did you find the problem? Sorry, it is probably obvious in the photos but I didn't see a problem.