03, F-150 V6, Knocking or Pinging sound at 65 + mph

Hello I wondering if any one has seen this before and can help. Picked up a use F-150 XL 2003, V-6 with 88k miles. Drove it around town, on and off the highway between on ramps for two weeks, and every thing sounded good. 3 weeks ago I had to take the truck on a 350 mile delivery run carrying mail. When I got out of town I set cruse control to 65 to see if it worked. With CC set at 65 and you start climbing the slightest of hills, like an over pass, the engine starts to Ping or Knock. This knock or ping is not like just a few sound, it is all the time until you starting down the other side, and to top that off if you get the truck past 65 to 70 mph the sound is all ways there even if you on a flat road. It sound like a 1979 Volvo diesel Engine. You can hear the sound over the car stereo, that is how loud it is. I turned off the CC and it still happens with me in control of the gas.
Only thing I tried before taking it to the dealer was to try loading down the truck by driving up a hill in Third and Second gear really slow before stalling it and I never hear that sound. It did sputter and shake a lot as it should. The truck is at the dealers now and has been there for 2 ½ weeks. I'd hate to get it back fromdealer saying it is normal for a Ford. Is this engine just shot ??

Any one seen this before, Thanks

Terry
Junkboyy999

 

I have ran into this before. And I am sorry but this problem was probably there bfore you bought the truck.. I work for a used car dealer that fixes everything mechanically wrong with a car and we came across this about a year ago.. same truck 2003 with the 4.2L v6. a few master tecks thought it was a cat or possibly a rocker arm... Then i was told fix it what ever it takes. I found a cracked wrist pin and excessive carbon buildup on CYL 5. The truck had only 65K on it and per our standards we put a new motor in the truck for the fix. so after spending 2K on cats and more labor on engine teardown we fixed it by replacing thelong block.

 

My Explorer did same thing, but it was the MAF sensor. When it was removed the silver wires were covered in black dust. Once cleaned the knock went away and I had much more power as well.

 

Thanks for the words of wisdom Green and Nut. Sad thing is I had to make my first payment on a truck all ready with it still sitting at the dealers. Today makes 3 weeks. Might have to check in to the lemon laws in Kansas and see if I can get out of the deal. Man, why did I trade in my Plymouth mini van

If they gt it fixed I post the Fix. I think the fix will be to buy a Dodge

Junkboy

 

If you purchased it from a dealer, I would imagine that there is some sort of "lemon law" that applies.

 

Hey junkboyy999

What is goin on with the truck. what did your dealer come up with. Did you get it back yet.

 

Hey Guys/Gals

Well, I got the truck back Friday before the weekend. It looks like they fixed it. Fingers are still crossed. The first mechanic looked and tried a few things but no luck. Later the truck was given to the master mechanic to look at. He researched and found a TSB ( Technical Service Bulletin ) out for the Following.

TSB 07-16-17
TITLE
Spark knock under light loads and acceleration - 3.8L, 3.9L, and 4.2L - Split port intake manifold Runner Control ( IMRC ).
This TSB covers

FORD
2001-2004 Mustang
1996-2003 Windstar
1997-2003 E-150 and F -150
2004-2007 Freestar

MERCURY
2004-2007 Monterey

ISSUE
Various vehicles equipped with a 3.8L, 3.9L, or 4.2L engine and a Split Port IMRC may exhibit spark knock under light load and acceleration.
This bulletin has you look at the IMRC actuator Rods to see if they are connected properly and if not replace them and add new retainers clips.

I did not get a chance to talk to the master mechanic, but from what I gathered from the Rep at the counter, the rods have ends that either melt or deform from heat and use over time ( or where the rods connect it gets deform ). This does not allow both intakes to get the same mixture of gas and air under the right condition. There is a small picture of where the rods attack on the TSB printout, and to me, it looks like plastic grommets "retainers" two white and two red.

How about this 02Green, does this sound about right?

So far it is running like a champ.

I hope this information can be useful to some others.

 

Sounds good to me. I have naver heard of this tsb. thanks will keep on file