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#1
10-15-2008, 06:01 PM
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'02 loud clicking/rattle on high rpm
After the sweet success of diagnosing the vacuum codes and misfires with the help of the forum, now my poor Winnie is making a nasty lifter type rattle on higher rpms. Very noisy, just had the oil serviced after about 4400 miles.
It seems to happen on the 'downside' of the rpm rev up if that makes any sense. Just looking for some advice on whether we are looking at a total rebuild, maybe oil treatment settles it down, spun bearing, blah blah blah. It definitely sounds like its near the top of the engine and not a catastrophic bearing/cylinder failure but I'm just a rookie. Not too familiar anymore with what lies beneath the valve covers, although I did succuessfully pull off the isolator bolt repair so I'm not inept. Solutions? JDPK 
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#3
10-15-2008, 06:27 PM
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Re: '02 loud clicking/rattle on high rpm
Did you notice when you had the air intake manifold apart, was the upper two plastic pieces clipped together ... or the more modern version, the two pieces glued together? The earlier clipped-together version can be a noise maker.
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#4
10-15-2008, 06:48 PM
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Re: '02 loud clicking/rattle on high rpm
Defininitely not spark knock. This is REALLY loud when it gets going. That's why it sounds like a noisy lifter? if those still exist?.
As to the plastic pieces, I cant honestly recall but this noise is specifically tied to engine rpm as far as frequency goes. i.e.-when revved, the clicking goes faster...... It begins on start up when the engine revs after the key is turned, then gets quieter, then can be heard again over about 2000 rpm when the engine goes through gears. Basically it sounds like it doesn't have any oil, but it just got serviced. And yes, it does have oil although I don't know for sure they put the Ford reccomended viscosity in it. (MIDAS)  JD
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#6
10-16-2008, 12:39 PM
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Re: '02 loud clicking/rattle on high rpm
I'm willing to bet it's the plastic upper intake manifold. I replaced the one on my '01. But mine knocked like crazy after a cold start (scared the $h!t out of me when I first heard it). I bought a new one on eBay for $60 or so.
EDIT: there's one right now on eBay for $83.95 with free shipping.
__________________
*Twin Cities MN*
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#7
10-16-2008, 12:52 PM
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Re: '02 loud clicking/rattle on high rpm
Road Rascal,
Was you intake cracked? split? or what? Was it the outer cover or the plastic ones inside the plenum? The noise I am getting seems to be directly tied to rpm which is why I thought lifter, valve, or other component.
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#8
10-16-2008, 04:49 PM
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Re: '02 loud clicking/rattle on high rpm
The six-barrel "horn" is merely clipped to the upper in the early version. The clips are molded into the horn detail. Over time they tend to weaken and break .... especially when the bolt operation is done.
I "glued" mine back in place using daubs of RTV. Seemed to work.
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#9
10-16-2008, 05:58 PM
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Re: '02 loud clicking/rattle on high rpm
It looked like one of the clips on my intake broke. Even though there wasn't much movement between the two parts, it was enough to make a lot of noise. I probably could have glued the two pieces together I wasn't going to mess with it and just put a new one on.
__________________
*Twin Cities MN*
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#10
10-17-2008, 04:05 PM
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Re: '02 loud clicking/rattle on high rpm
No luck. I needed a quick answer before I left the vehicle (and family back home for a week) so I took it to the stealership to have a look. Not the plenum or the plastic intake. They say it's deeper and wouldnt even reccomend messing with it. Offered re-man engine installed for $4600.00.
The worst part is we just got it running good last month after a long series of EGR/vacuum issues.
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#11
10-17-2008, 08:07 PM
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Re: '02 loud clicking/rattle on high rpm
jdpk
Is the van worth 4000.00? Drop in a used engine.
__________________
******************************************* Wiswind's Windstar repair pics http://community.webshots.com/album/201931518cScpNK Photos of my repairs: http://dansautopictures.shutterfly.com/ Check this out:http://threewheelmotorcyclemetro.shutterfly.co A must read about problems Windstars have: http://www.automotiveforums.com/vbul...d.php?t=672854 95 Windstar 240,000+ 98 Windstar 136,000+ 09-25-2008. 85 Dodge 1 Ton Snow mover gas hog 91 Mazda Protege free beater SW MN
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#12
10-19-2008, 06:36 PM
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Re: '02 loud clicking/rattle on high rpm
Good point, not worth the big money. Might shop around for used engine. I was looking at jasper site, they said something about needing a tranny component from the original to mate to the new engine. Any idea what this may be? Maybe I'll shop for a engine/tranny combo used? Dont know, but it will be alot of fun to try. ;-) Might need a winter hobby.
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#13
10-20-2008, 10:00 AM
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Re: '02 loud clicking/rattle on high rpm
Did the dealership actually look inside the intake manifold ... or did they just give you their "expert" opinion. I hate to see you replace an engine ... instead of you using $.05 worth of RTV.
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#14
10-23-2008, 10:06 AM
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Re: '02 loud clicking/rattle on high rpm
When I first heard the knocking noise on my van I thought it was something much worse. It did sound like a deep engine knock.
__________________
*Twin Cities MN*
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#15
10-24-2008, 02:54 PM
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Re: '02 loud clicking/rattle on high rpm
RR-
Let's put it this way, they initial fee was $85 and they called to say they needed another 85 to rule out the plastic so i would hope the actually turned some screws. With yours, was it the ( I'm going to use the wrong words here) top cover, the peice underneath, or the plastic plate where the isolator bolts are? Cracked? beat up? busted or what? I'm trying to think of how that could create the noises
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