I bought this 03 Ford Expedition cheap from someone on craigslist that had just rebuilt the engine (replaced the block with one from an 05, reused the heads, and had new pistons/rings installed, but I don't think he honed the bores) and had what he said was a rocker arm tapping because he heard it fall off. He didn't want to start it because he said he didn't want it to possibly cause further damage and I didn't push the issue because even at fair blue book value, adding the cost of replacing the engine by a shop shouldn't have put me in the negative. After pulling the valve cover I found nothing wrong with the lifters and the cam was fully installed so I put it all back together and started it up. It started knocking almost immediately and I'm kicking myself for not recording it so everyone could hear/see what it sounds like and where it comes from, but listen for the sound on the top, sides, and bottom of the engine to help figure out where the noise is coming from. This one you could hear from the bottom and sides the best even though it was loud on top too. I bought it because it was a good deal, I like expeditions, I have an uncanny ability to diagnose/fix things, and I've been working on cars as a hobby for ~10 years.

As you can see from what I found, the guy never tightened the connecting rod bolts on one of the connecting rods. I'm going to get new bearings for the one and new bolts as well. I've finally decided to do a torque check to verify which ones are actually torqued. The spec is 32lb/ft + 90-120 deg so if I set the torque wrench value to say 45-50lbs/ft and it just clicks, I should hopefully be good.

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