Anyone have an idea as to what I'm dealing with here??? I have a 2002 Explorer w/ a 4.0L engine in it.
Just recently a noise has come up when I crank the engine after it's been sitting awhile and has cooled off
or first thing in the morning. The engine has 155,000 mi. on it.
It's a rattle that is impossible to determine where it's coming from. It sounds like the noise one makes when
the starter drive doesn't completely disengage after starting. (that's not it though). I've removed the belt and
started it w/o the belt on it and the noise is still there. It only lasts for a minute or so then it gets quite. Once
warmed up it doesn't do it...
Any ideas??

Thanks,

The 4.0 SOHC engines have an issue that was address by Ford that states the timing chain cassette is the "noise" you are experiencing. Ford has expressed that the issue is not a problem that would cause damage or reliability of the engine but may cause disappointments in the owning of the vehicle. This matter was covered in an extended warranty until 2001 April 30th. or 6 years to 72,000 miles after the warranty of the vehicle. This was an issue in all 4.0 SOHC from 1997 to 2002. As I've stated this was only an issue addressed to appease owners of a quiet engine not an issue that is going to be harmful. I know this because I to have a 2002 Explorer Sport with 155,000 and I am a picky guy since having an Intrepid with the dreaded 2.7 that blew up rebuilt and started making "tapping sounds" again. But anyway, my Ford is the best vehicle I have owned and even with the mileage and the noise at startup I would drive it ANYWHERE. I just start it when cold and let it idle until 30 sec later the noise is gone. For 155,000 miles I think the engine is holding up better than any import around and could not be more pleased.

Hope this puts your mind at ease and good luck with your Explorer :)