Originally Posted By: MNgopher
You've started down the road and it certianly sounds like a phaser issue. I own an '04 f150, which I bought fully understanding this issue. My engine is noisier than I was previously used to and makes that diesel like sound when fully warmed up in confined spaces. Based on everything I've read and can get my hands on, I'm choosing to do nothing different. No $2000 repair bill that may or may not remove the dieselish sound. Regular oil changes every 4-5000 miles with name brand 5w20 oil and a motorcraft filter. Most cases of failure I've seen have occured when the engine was neglected (lack of oil changes, and debris builds up in the VCT system) or driven hard. My truck appears to fit neither of these scenarios.
Ford did ackowledge the issue and made a change to the phasers sometime in 2005. They continue to indicate it is a noise issue only.
Life is a lot easier once I figured out how to stop worrying so much...
+1 ... I have an 04 of and it makes the sound when warm. Mine has been babied by previous owner with Penz YB 5-20/Fram TG filter and oil change every 3k. I've had it a year and 10k miles (76k now) and go the route of 4k with MC 5-20 and MC filter or P1 filter.
From what I can gather from reading up on a lof of guys with the VCT issues it seems the upper end of the 5.4 3V really like to be taken care of and if you don't, it will show you problems! Those passages seem to get clogged up pretty easily. Of course not all were abused but a lot of them seem to have been neglected.