Seen many, many many many posts on here about the 4.0 sohc timing chain rattle, so here is literally everything you need to know about it.
I have recently rebuilt the top end of my 4.0, so do not hesitate to ask me questions on this thread or via PM if you can not find an answer looking through all of the following:
Im not posting a how to as there are many links about causes/diagnosis/repairs scattered throughout the internet. Here I am going to post about every link known to man about how to deal with the infamous SOHC rattle.
First off:
THE FAULTY TIMING CHAIN TENSIONERS WERE FOUND ANYWHERE BETWEEN 2001~2004, AFTER THAT, FORD USED THE UPDATED HARDWARE. THAT STILL DOES NOT MEAN YOUR 2005+ 4.0 WONT DEVELOP PROBLEMS. ALL 4.0 SOHC OWNERS SHOULD REPLACE THE PLUNGER TYPE SCREW-IN TENSIONERS EVERY 70,000 MILES OR SO TO PREVENT CHAIN SLACK, WHICH KILLS THE GUIDES!
If the rattle is
ONLY on startup, and never at idle, or at any other RPMS's it is most likely the tensioners. They screw into the block and are ~$80 from ford. Much better than having to possibly remove the engine to replace all of the guides.
They look like this:
If that does not solve the problem, look here:
If you hear the rattle coming from the front of the engine, it is
MOST LIKELY coming from the primary cassette/tensioner (the chain that connects the crank to the jackshaft and drivers side cylinder head)
Here is a picture of one that is fubar:
Here is one that has been corrected using the updated componets:
If this is your problem, then you DO NOT HAVE TO REMOVE THE ENGINE!! all you have to do is pull the front timing cover as you would with a pushrod engine. Also, if the drivers side guide is broken, you can replace it with the engine in as well.
Now, if the rattling is coming from the rear passenger side, you'll either have to remove the engine or transmission in order to replace the
chain and guide set,
HOWEVER it
IS possible to replace the rear
GUIDE without removing the engine. Note, guide only. To remove as well the chain you have to at LEAST remove the transmission in order to pop off the rear jackshaft sprocket cover in order to remove the bolt holding on the sprocket. The ford OTC-6488 tool is designed so that you can remove the rear cam sprocket, replace the guide, and re-time the cams with the engine in the vehicle, remind you, it'll be cramped, but it is possible. In fact, using alldata, the service procedure has you replace the rear guide with the engine in. There have been people who have successfully replaced the rear guide with the engine in.
Now, here are links to all of the SOHC replacement threads. I highly recommend using a database like all data, or a Haynes or factory ford service manual along with these links. A lot of these links are for 4.0 explorers, but the process is essentially the same, however, use ranger 4.0 torque specs as the explorers have had two types of 4.0's in them; Job 1's with the aluminum valve covers, and the Job 2 explorer 4.0s which were similar to the 2001+ ranger 4.0's, so be careful when you search torque specs. To play it safe, use alldata or a service manual.
timing chain replacement walktrhough PDF:
http://sohcreplace.blogspot.com/2008...97-2005-4.html
Links to SOHC timing chain related threads, search through all of them until you find what you need:
http://www.explorerforum.com/forums/...d.php?t=278100
http://www.explorerforum.com/forums/...d.php?t=316471
http://www.explorerforum.com/forums/...d.php?t=287416
http://www.explorerforum.com/forums/...d.php?t=269442
This guy has many videos on replacement of the 4.0 SOHC timing
chain/guides/tensioners. Here is the link to his youtube channel. with a
long list of videos on how he did it.
https://www.youtube.com/user/cruzroy...y=timing+chain
4.0 SOHC TIMING CHAIN PART NUMBERS
Jackshaft/primary timing chain kit 2U3Z6D256CA includes:
Crankshaft bolt harmonic balancer E7RY6A340B
Tensioner-engine jackshaft chain YL2Z6L266AA
Gasket-cylinder/timing front cover F77Z6020AB superseded by 1L2Z6020AA
Sprocket/gear-engine jackshaft/intermediate 2U3Z6M264AA
Guide-engine jackshaft chain 2L2Z6K297AA
Bolt-jackshaft sprocket bolt F77Z6M264BA superseded by 2L2Z6279AA (included when 2U3Z6M264AA is purchased)
Sprocket/gear-crankshaft two wheel drive 2L2Z6306BA
Chain-engine jackshaft F77Z6268AB
Bolt-camshaft sprocket right hand
Bolt-camshaft sprocket left hand F77Z6279BA
Left/front timing chain cassette assembly 7U3Z6A257A includes:
Timing chain
Guide assembly YL2Z6M273AA superseded by 7U3Z6A257A
Bolt-guide assembly upper mount
Sprocket/gear-camshaft
Sprocket/gear-jackshaft front
Right/rear timing chain cassette assembly 4L2Z6M290AA includes:
Timing chain
Guide assembly
Sprocket/gear-camshaft
Sprocket/gear-jackshaft rear
Intake manifold gaskets: 1L2Z-9461-CA
Left timing chain tensioner 7U3Z6K254B
Tensioner metal O ring XU2Z6M252AA
Right timing chain tensioner 7U3Z6K254A supersedes XU3Z6K254BA
Right timing chain guide assembly upper positioning bolt F77Z6U000BA
Jackshaft rear sprocket retaining bolt W703167S430
Cover assy/rear of block jackshaft opening plug F77Z6026AB
Left cassette assembly lower mounting bolt W500100S300
Jackshaft chain guide mounting bolt W500100S300
Sprocket/gear-crankshaft inner four wheel drive F77Z6306BE
Sprocket/gear - crankshaft outer four wheel drive 2L2Z6306AA
Balance shaft chain guide F77Z6K297BC
Balance shaft chain tensioner 1L2Z6L266AA
Balance shaft chain F77Z6268BC
Balance shaft assembly 1L2Z6A311AA
Seal-front timing cover E6TZ6700A was superseded by 5H2Z6700AA
Seal-rear main crankshaft F5TZ6701A
Gasket set-valve cover F77Z6584AE
Gasket-lower oil pan 4L2Z6710AA year 2000+ F77Z6710BA year 1997-1999
Gasket-upper oil pan/reinforcement section F77Z6710AA
Block cradle retaining bolt seal F77Z-6734-AB (Listed as engine oil drain plug gasket)
Left camshaft F7TZ6250AEE was superseded by 7L2Z6250D
Right camshaft F77Z6250AE
Exhaust manifold outlet bolts (M12-1.75X54.5 H) N811747S2
*NOTE: I am not responsible for damages done to your vehicle, repair at your own risk*