Noisy Aluminator engine

[WesStang]

Folks, I'm looking for some help in diagnosing my very noisy Aluminator engine.

Here is a link to the video:

YouTube - NoisyAluminator.wmv


Details are as follows:
M-6007-A46SC (FRPP Aluminator long block for supercharging)
Built 8/2/2010
S/N R07400588
Installed 12/2010
200 miles on engine, 15K on car
Engine is completely stock, except for full exhaust and a K&N filter.

Issue #1
The engine sounds like a diesel while warming up. (It did this a little at new, but is getting worse.) It is quiet for the first minute or two after startup, then rapidly starts “clacking.” It is very loud, and I can hear it echo off buildings with the windows down, and I can hear it with the windows up inside the car. It is mostly at idle, though I can also hear it driving at 2500 RPM. Once the engine is completely up to operating temperature, I can hardly hear it.

• Main oil pressure is 90 PSI at startup, and 30 PSI at operating temp. I cannot remove the pugs on the heads to check head pressure, but based on using my ears and stethoscope, the valvetrain is not the source.
• Engine has been filled with 5w30 conventional oil since new
• With a stethoscope, the noise is loudest touching the block, near the freeze plug at the rear driver’s side of the engine.
• Depressing the Clutch pedal has no effect.

Issue #2
There is a valve ticking on cylinder #3 or #4. I can’t get my stethoscope on those header primaries to verify which one. It is most audible at idle. Off idle, the rest of the engine noise covers it up.

The noises of this engine are disturbing, and much louder than I feel is “normal” (especially for a $6500 engine with only 200 miles!)

I appreciate your help.

--Wes

 

[COBRA90GT]

...The engine sounds like a diesel while warming up...

You aren't kidding - the cold start clacking sounds VERY loud.


Was this engine ordered from Ford Racing or another vendor? If so, have you contacted them RE the noise? Their reply?


I suspect they might say it's "normal" due to "piston slap," just to avoid the issue. Wish I could offer more advice, but I remember hearing about corporate using the CYA of "cold start" piston slap as being "acceptable" many years ago...hope that's still not their position on the matter.


G'luck with resolving it.

 

[WesStang]

Update:

To make a long story short, Ford Racing Engineer, Robert Deneweth concluded there was something amiss, and had Rehagen Racing remove the engine and ship it to his lab. He took the time to make a thorough analysis, find the source, and correct the issue. All the while, he kept me thoroughly appraised of the progress. Only when he was sure he found the cause, he re-assembled the engine, Rehagen Racing re-installed it and arranged for me to pick up my car. The engine is smooth and quiet, and I am very pleased. There's a little valve click on the passenger side, but it's only noticeable if you're anal-retentive like me, and are sensitive to the issue. Overall, I'm very pleased!

What impressed me most, however, was that everyone involved—Rehagen Racing, and Ford Racing’s Steve Horn and Robert Deneweth—shared a desire to “make it right.” Notably, I was assured by several people that Robert Deneweth “is an enthusiast, so you’re in good hands.” I could not agree more. Having worked in the performance automotive aftermarket, this further reinforced my belief that having “enthusiasts serve enthusiasts” assures that customers are treated well. They completely understand the customer’s position, since they are often customers themselves.

I also get the impression that Ford Racing "learned something" with my engine that they will apply from now on. All is well that ends well!

 

[wmburns]

Do you mind posting what Ford found wrong. There's part of me that would like to do a project with this crate motor. Frankly, it scares me to think about having a bad outcome when this amount of $$ is spent.

 

[COBRA90GT]

WesStang - Glad you got it sorted out.

Kudos to the Ford Racing employee for helping to properly investigate the matter. All too often we hear horror stories about the manufacturer declining to assist the customer when a problem arises, especially when it relates to a "performance" product/part and blaming it on the install or user error, etc, etc.

I'm sure others would also be curious to know what the cause of the problem was (if anyone else happens to come across this thread via the "search" feature in the future, etc), if you don't mind posting the reason...