So, my grandmother bought an 04 ranger a few years back with 80k on it. Since then she has drove it to around 140k and it developed the rattle at startup. I informed her, a set of OEM ford tensioners would resolve the problem. I took and installed new ford tensioners last night. 7u3z6k254a and 7u3z6k254b. Upon startup I had a little rattle, as they had some air in them yet. But they quickly quieted up. Drove it home that night, (yesterday) and had no issues. Took it to work this A.M. no cold start rattle. Let it sit 4/5 hours before lunch. Had cold start rattle at lunch. Kind of upsetting, but not the end of the world
Letting it warm up, it began rattling at idle. I then shut it off, and re-started it and the noise was gone. I then took it to lunch and had no issue since. Do I have a bum new tensioner? Did installing new tensioners destroy the guides? I'm kind of surprised new tensioners caused this. The truck had a stack of receipts for service done, and maintenance performed religiously. My grandmother followed that same religious service. I wouldnt think an 04 should have issues at 140k should it? It's been driven like a grocery getter since 80k miles. I dont want to diagnose bad cassettes... Any Ideas?

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2002 4.0 4x4 auto.
Black Rock steelies, 32" Cooper Discover AT/3
Power leather buckets, Full length console
EATC, OHC, Lighted visors, Wite cluster
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04 is still in the era of crap tensioners/guides/casettes. Sounds like you simply did not fix the problem and will need go back in and do do a full front and rear timing kit with all the updated tsb components.

Did you replace the rear one aka pull the engine.

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