Timing Tensioner problems of the 2003 Ford Explorer

Rattling noise in 4. 0 liter-sohc 2003 Ford Explorer XLT. Dealer replaced rear tensioner. Noise remained. Diagnosis said engine noise is coming from rear cassette and possibly front one. Engine would have to be removed and taken apart to replace timing chain cassettes for @ $4k. The car only has 53,070 miles on it. Online search verifies an obvious issue pattern and complaints to an inferior quality cassette material requiring labor intensive engine removal repair.

Timing chain tensioner failure with valve cover damage provoking oil leak and heavy smoke out of the engine, wich lead to spill of oil in the highway (oil dropping) and engine out of sequence due to a plastic "casset" tension break, I have read over the internet alot of complains about the same incident.

Timing chain broke, with no warning, bent all the valves and wasnt even driving it. Had just started the car in the garage and backed out of driveway with car idling very rough. Pulled back in driveway and oil was pouring out underneath, due to chain had busted the valve cover. Well had to pull the motor, replaced guides, cassettes, and tensioners, with 2000. 00 just in parts alone. Had car back from mechanic not even 3 weeks and engine started knocking as if a rod was knocking. Went back to mechanic and tensioners were the cause of timing-chain "clank". Apparantly they (Ford) designed these tensioners with "plastic" guides which shred off into the hydraulic tensioner pick up tube therefore clogging up the hole for oil to get to chain and will continue to do so unless you get updated tensioners directly from Ford at 100. 00 each. There are 3 timing chains and multiple tensioners as well, which continue to go out after 30,000 miles and need replacing, which most can be replaced with motor in but some cant therefore I have had motor out twice now, at 2500. 00 each time. There was an onp to owners but Ford would only cover cost up to 100,000 miles and only if owners complained!! otherwise they would not fix!!! well this is a bad design on Fords part with plastice tensioners to guide your timing chain!!! now they have updated with a tougher nylon "plastic". But have not recalled the old ones so unless you order dealer parts you receive the old parts which are no good and will end up making you spend more money and for the last 12months, I have had my car 3 weeks due to cant afford the enormous repair bill, which Ford knew about all along, but failed to recall plastic parts unless someone complained. According to my research it has been an ongoing problem since the 1996-2006 year model explores with 4. 0 sohc v-6 motors. Something definitely needs to be done!!!.

Vehicle failure problems with 2003 Ford Explorer. While driving the vehicle stalled in an intersection. The vehicle was taken to the dealer where it was determined that there was sludge in the engine. The dealer insisted that the consumer's neglect was the caused of the failure and if he refused to purchase a new engine from them they would void manufacturers and extended warranty. The consumer indicated that he took care of his vehicle performing all the regularly scheduled maintenance. The consumer believes this problem is related to a defect in the timing chain tensioner.