It’s a longer story but here goes.
This engine has 171,000 on it. I’ve had it since 124,000. Never used any oil & has never smoked or anything unusual. Put a new cat & oxygen sensors in about a year ago. Put head gaskets in about 8 or 10 thousand ago. Started getting a noise sounding lower in the engine. It is now a knocking sound. When driving there is the knocking sound, then around 2500 RPM it sounds like the valves are starting to float. Like the timing way advances all of a sudden. Soon as the rpms drop the valve sound goes away. I haven’t reved it any higher to see what happens.
A guy at work hooked up a reader to check codes. No codes but it said the coolant sensor & the EGR weren’t in specs. He down loaded all the information & sent it to a tech he knew, this tech said a bad MAP Sensor could cause these symptoms without throwing a code. So I think I’ve been on a wild goose chase trying to track down all my vacuum lines to see if a MAP sensor would be hiding on the other end.
I originally was thinking bearing, rod problem, but that is even funny. This engine has always had very good oil pressure & still does. The pressure has never dropped, never flinched. It’s got clean oil in it with no sign of bearing wear. Never have heard a sound like a bearing trying to spin.
That’s where I’m at. Trying to see if I’ve got any other options before pulling an engine.
Any ideas?
Why new head gaskets?
I had a Fan Clutch going bad, it gave a noise and vibration above 2,000rpms.
With engine cold I would rev engine and see if you can duplicate any noises in the driveway.
Then remove serpentine belt, or loosen it, restart engine and repeat test, without the fan noise you should be able to hear better but also see if any noises were coming from pulleys or fan that are no longer moving.
Battery light will come on, that's ok, and a few minutes without water pump won't hurt anything on cold engine.
Knock noise can be an exhaust leak at manifold.
To check Rod bearing issue, make sure you can hear knock, then unplug one spark plug wire at a time, if a rod is knocking that noise will disappear when that cylinder stops firing, the "Knock" is from the rod slapping the crank when cylinder fires.
Just FYI, Oil pressure on Fords after about 1986 is shown as either on or off, the sender on the engine is a switch, below 5psi of pressure the switch is off, above 5psi is on.
So gauge shows low(0) or mid-range, any movement of the gauge, is from alternator voltage fluctuating, so can be RPM based, but it's not oil pressure based.
IMO, this "faux gauge" setup is worse than an idiot light because people think it is reading actual pressure.
The expression "it sounds like valves were floating" is odd, floating valves wouldn't make a noise, you feel the engine power curve drop when valves float, but there would be no noise just the lack of power since valves are not closing all the way.
When you replaced the Cats, was the muffler replaced?
Collapsed/clogged exhaust system limits RPMs