Basic info for those who own any 4.0 SOHC engine....
Some info here:
http://www.explorerforum.com/forums/...d.php?t=163298
I'll update as I gather info and links.
As you can see they use plastic guides on the timing chains. They wear over time and start to make noise upon startup and sometimes while driving. It sounds similar to spark knock or a "rocker arm" tick...
The replacement of the "cassettes" is quite involved and requires removal of the engine or transmission to do the rear chain on the passenger bank of the engine... I recommend removing the engine and doing it on a stand as it is easier to align the chains without standing on your head in the truck.
To setup the timing you will need the OTC fixtures. There are no keyways on the cams or jackshaft. I have the Ford master kit and would lend/rent it if someone needs it. I rarely use it anymore.
Some 4wd engines used a balance shaft and have 4 chains, if you have it out, do the guides on it too.
I have seen this issue cause chain failure and major engine damage if left alone long enough. If your truck is making the noise it's a good idea to research any TSB's or recalls that provide dealer assistance as it is a very costly repair.
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